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Additive Manufacturing in
Aerospace & Defence
Facts and Forecasts
Dr Bryony Core
1
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Helping you profit from emerging technologies
2
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Additive manufacturingHow did we get here?
Image source: waste-management-world.com
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The seven different types of AM:
Process Related acronyms
Vat Photopolymerisation SLA, DLP, CLP, CLIP
Material Extrusion FDM, FFF, TPE, ADAM
Material Jetting Polyjet, MJP
Powder Bed Fusion SLS, SLM, DMLS, EBM
Directed Energy
DepositionDED, RPD, EBAM
Binder Jetting MJF, SPJ
Sheet Lamination LOM, UAM, CBAM
…3D printing is defined as a form of Computer Numerical Control (CNC) in which a product is
manufactured additively through the interaction of software with physical hardware such as a scanner,
printer and materials.
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0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
1,600,000
2011 2012 2013 2014 2015 2016
Cum
ula
tive
su
m o
f p
rin
ter
sa
les
Industrial
Desktop
5
Installed base is a foundation
for the demand of AM
consumables such as
materials and software.
The breakdown of installed
base according to desktop
(<$5000) or industrial printer
types has shifted dramatically
in the past five years.
Desktop printers now
constitute the overwhelming
majority of the installed base of
all 3D printers.
The media frenzy of 2012
established the term 3D
printing in common lexicon and
desktop printers have seen the
greatest boom in demand.
The explosion of interest in 3D printing
In 2016, desktop printers constituted 95% of the total installed base of 3D printers globally.
55%45%
5%
95%
Desktop
Industrial
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History of polymer AM: the rise of the hobbyist
3D printing: (Worldwide)
makerbot: (Worldwide)
ultimaker: (Worldwide)
1986 – Patent protecting SLA granted to Chuck Hill
1986 – Patent protecting SLS granted to Carl Deckard
1989 – Patent protecting FDM granted to Scott Crump
2009 – Stratasys patent expires and Makerbot is
founded
2013 – Makerbot acquired by Stratasys for $400m
2014 – Makerbot become the most popular brand of 3D
printer in the world, soon overtaken by XYZPrinting
2017 – Over 200 individual desktop TPE printer
manufacturers known
Google Trends
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Additive manufacturing metals
Metal additive manufacturing was commercialised in the 1990s by EOS who developed powder-bed direct metal
laser sintering and commercialised their first printer in 1995.
Arcam AB commercialised EBM technology in 2003.
2017 witnessed a flurry of new technologies commercialised.
1995 2000 2005 2010 2015
EOS Optomec
SLM Solutions
Voxeljet
Arcam AB
Phenix
Realizer
Concept Laser
Fabrisonic
3D Systems
ExOne
Sciaky
DMG Mori
Trumpf
Norsk
Titanium
Markforged
Desktop Metal
Cytosurge
Vader
3DEO
Admatec
ORLaser
Xact Metal
Additive Manufacturing
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Unit sale per annum are set to
almost double between 2018 and
2028 for industrial printers.
In total, industrial printer market will
see a CAGR between 2018 and
2028 of 6.2% to be worth $22 billion.
Metal printers will fuel this growth:
metal + polymer extrusion and metal
binder jetting printers will experience
a CAGR of 41 and 43% in this
period.
Material jetting and sand binder
jetting printers will see the most
pronounced decrease in unit sales.
8
AM isn’t going away any time soon
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
2018F 2028F
Un
it s
ale
s
Vat Photopolymerisation(polymer)Powder bed fusion(polymer)Powder bed fusion (metal)
Material jetting
Extrusion (polymer)
Extrusion (metal)
DED Welding
DED blown powder
Binder jetting (sand)
Binder jetting (polymer)
Binder jetting (metal)
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Additive manufacturingAdvances and new developments
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A barrier to adoption of additive manufacturing in aerospace is the
rigorous certification requirements for components on aircraft.
Norsk Titanium have completed certification of their Rapid Plasma
Deposition process by the Federal Aviation Authority (FAA).
Boeing have placed a production purchase order with Norsk
Titanium using RPD for a part on the 787 Dreamliner.
Norsk Titanium estimate that the 3D printed titanium parts
represents a potential manufacturing cost reduction of $2 to 3
million per aircraft for Boeing.
10
Boeing 787 Dreamliner: Ti-6Al-4V structures
Application case studies
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Altair Hyperworks is a simulation software package that has been used to
algorithmically optimise product design solutions for over 30 years.
Collaboration with a number of printer manufacturers and end users have
showcased their ability to apply these concepts to AM.
Using Altair’s topology optimisation and design packages, OptiStruct and
ProductDesign, they designed an antenna mount for RUAG Space, printed on
an EOS M 400 system.
Compared to the existing support mount, the 40 cm long 3D printed component
offers 43% weight reduction from 1.626 to 0.936 kg and increased eigen
frequency of 70 to 90 Hz.
Altair do not provide software solutions specifically required for additive
manufacturing, such as g-code generators, but do provide middleware to allow
printer load management.
11
Application case studies
RUAG Space and Altair: antenna mount
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IDTechEx spoke with prototype manufacturer Hofmann
who designed and manufacture a component for BAE
Systems’ auxiliary oxygen supply system on the
Eurofighter Typhoon.
This supply tube comprises a single part and is capable
of withstanding pressures of up to 900 bar, significantly
higher than the standard operating and burst pressure
thresholds of 200 and 400 bar, respectively.
The original component comprised 5 parts, welded
together with semiautomatic orbital welding which led to
gas leakage and quality control difficulties.
Approximately 100 units are made p.a. and design
improvements to the radius of the inner tunnel with a
90° angle enabled by AM ensured gas was supplied at
a continuous flow rate.
12
Application case studies
Hofmann: oxygen supply tube
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At FIA2018, 3T RPD discussed the future of additive
manufacturing innovation that 3T RPD was
undertaking.
Their development of a copper chromium zirconium
alloy for powder bed fusion is unrivalled in industry: the
result of two years research and development, 3T RPD
have successfully developed the process to enable the
production of a unified rocket nozzle with integrated gas
channels (pictured left).
Forthcoming innovations to watch out for later this year
include the world’s largest topologically optimised
structural component that was manufactured on two
powder bed fusion printers.
13
Application case studies
3T RPD continue to push AM boundaries
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Additive manufacturingThe Forecasts
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The Forecasts
15
Market size of AM in aerospace & defence
2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030
C919 C929MoMA330NEO R-80B777x
35%
23%
11%
9%
7%
6%
9% Aerospace & defence
Healthcare
Automotive
Consumer goods
Energy
Construction
Other
Total AM
market in
2028F:
$38 billion $2B
$14B
$0B
$4B
$8B
$12B
$16B
2018 2028F
Materials Hardware and software
AM in aerospace & defence
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Additive Manufacturing
16
Drivers and restraints of growth
Market growth in additive manufacturing currently facing barriers in areas of cost, technical capability and education.
Lack of appropriate personal training in AM.
Price point of printers and metal powders is out
of reach of SMEs.
Restricted material choice.
Conformity and certification standards increases
cost and lead times
Significant post-processing required, including
support removal and hot isostatic pressing.
Macroscopic properties of AM parts not identical
to traditionally manufactured parts.
Restricted build volumes and speed limits
application to low volume production.
Existing investment in traditional manufacturing
PPE.
Affordable desktop metal printers increases
SME adoption.
Increasing awareness of additive manufacturing.
Improved part quality with inbuild monitoring and
quality control software.
New entrants to market due to expiration of key
patents reducing printer prices.
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The Forecasts
17
Additive manufacturing: technology roadmap
2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030
C919 C929MoMA330NEO
Local repairs
Spare partsCabin reconfiguration Lightweight structures AM designed airframes
R-80B777x
Increased production rates
Greater material range
Effective AM supply chainKey e
nab
lers
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Additive Manufacturing and
Lightweight Materials for
Aerospace and Defense
Dr Richard Collins and Dr Bryony Core
Technology assessments, player profiles and
strategies, market forecasts 2018-2028
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Dr Bryony Core
b.core@idtechex.com
www.linkedin.com/in/bryonycore
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