RMIT: 3D Printed Milling Cutter That Cuts Titanium Alloys, Thanks to Jimmy Toton

3D printing is walking its path slowly but surely into the field of aerospace and defense manufacturing. Due to the demands of high performance and rigorous precision, every step given in this direction has to be crafted to the detail to achieve perfect execution.

Jimmy Tonton, a PhD candidate from RMIT University of Melbourne, Australia, has achieved important progress in this field by developing high-quality cutting tools than can now be 3D printed. For this research, Toton has partnered with the Australian Defence Materials Technology Centre (DMTC) and industry partner Sutton Tools. The outcome of this collaboration is a set of steel milling cutters able to cut through Titanium alloys with the same or at times better results than conventional steel tools.

Picture of the high performance milling cutter

This is the high-performance steel milling cutter 3D printed by RMIT researchers. Credit RMIT University

Because the high resistance of metals used for aerospace and defense, creating an efficient cutting tool is quite challenging and expensive. The strength and high-quality execution required to perform those cuts let us imagine the numerous difficulties that Toton had to overcome to achieve a successful design. The milling cutting tool has to be strong enough to cut through metal while keeping the layers resulted from 3D printing unified and all its parts built strong enough to avoid cracks. It also must be finished to a very smooth surface roughness in order to remain functional. 

The set of milling cutters represent the first convincing demonstration of 3D printed steel cutting tools that can cut strong metals. Toton’s work is a clear demonstration of the technology´s potential achievement for the development of 3D printing tools. Consequently Toton has been awarded the 2019 Young Defence Innovator Award and $15,000 prize at the Avalon International Airshow.

Jimmy Toton inspecting his tool

Jimmy Toton inspects a 3D printed steel milling cutter. Credit RMIT University

The technology used to make the milling tools is  Laser Powder Bed Fusion, also called Laser Metal Deposition, Selective Laser Melting  and Direct Metal Laser Sintering. Which is an additive manufacture process in which metal powder is fed onto a metal base and a laser beam melts the material added forming a metal pool that layer by layer forms the object. This technique lets the object to be built with complex internal structures and demanding external surfaces. Although as we know metal 3D printing processes require several finishing and post finishing steps in order to work well. These may include tumbling for several days, HIP, precipitation hardening, shot peening and other steps. These kinds of cutting tools do not magically appear out of the machine but are a result of a number of process steps. 

Some of the potential that this project holds are improvements in productivity, time-saving in tool making, costs savings, reduction of material waste and the possibility of creating tools that fit a very specific purpose and in so doing overcoming supply chain constraints. This is all good news for manufacturing. Toton is now working towards establishing a print-to-order capability for Australia’s advanced manufacturing supply chains.

In his own words:

Manufacturers need to take full advantage of these new opportunities to become or remain competitive, especially in cases where manufacturing costs are high,”

“There is real opportunity now to be leading with this technology.”

DMTC Chief Executive Officer, Dr Mark Hodge, said:

“Supply chain innovations and advances like improved tooling capability all add up to meeting performance benchmarks and positioning Australian companies to win work in local and global supply chains,” he said.

“The costs of drills, milling cutters and other tooling over the life of major Defence equipment contracts can run into the tens, if not hundreds, of millions of dollars. This project opens the way to making these high-performing tools cheaper and faster, here in Australia.”

Sutton Tools Technology Manager, Dr Steve Dowey, said:

“This project exemplifies the ethos of capability-building through industrial applied research, rather than just focusing on excellent research for its own sake,”

RMIT’s Advanced Manufacturing Precinct Director and Toton’s supervisor, Professor Milan Brandt, said:

“Additive technology is rising globally and Jimmy’s project highlights a market where it can be applied to precisely because of the benefits that this technology offers over conventional manufacturing methods,”

Tooling and cutting tools may not be the first thing that you think of when coming up with 3D printed products. This showcase of their use indicates just how versatile 3D printing can be. Toton has shown us that parts that are not traditionally thought of as high value are still mission critical enough to 3D print in costly metal printing processes. We expect many more people to apply metal 3D printing to metal and polymer consumables and tools in the coming years.

3D Printing News Briefs: February 8, 2019

We made it to the weekend! To celebrate, check out our 3D Printing News Briefs today, which covers business, research, and a few other topics as well. PostProcess has signed its 7th channel partner in North America, while GEFERTEC partners with Linde on 3D printing research. Researchers from Purdue and USC are working together to develop new AI technology, and the finalists for Additive World’s Design for Additive Manufacturing 2019 competition have been announced. Finally, Marines in Hawaii used 3D printing to make a long overdue repair part, and Thermwood and Bell teamed up to 3D print a helicopter blade mold.

PostProcess Technologies Signs Latest North American Channel Partner

PostProcess Technologies, which provides automated and intelligent post-printing solutions for additive manufacturing, has announced its seventh North American Channel Partner in the last year: Hawk Ridge Systems, the largest global provider of 3D design and manufacturing solutions. This new partnership will serve as a natural extension of Hawk Ridge Systems’ AM solutions portfolio, and the company will now represent PostProcess Technologies’ solution portfolio in select North American territories.

“Hawk Ridge Systems believes in providing turnkey 3D printers for our customers for use in rapid prototyping, tooling, and production manufacturing. Often overlooked, post-printing is a critical part of all 3D printing processes, including support removal and surface finish refinement,” said Cameron Carson, VP of Engineering at Hawk Ridge Systems. “PostProcess Technologies provides a comprehensive line of equipment that helps our customers lower the cost of labor and achieve more consistent high-quality results for our 3D printing technologies, including SL (Vat polymerization), MJF (Sintered polymer), and ADAM (Metal) printing. We vet our partnerships very closely for consistent values and quality, and I was impressed with PostProcess Technologies’ reputation for reliability and quality – an ideal partnership to bring solutions to our customers.”

GEFERTEC and Linde Working Together on 3D Printing Research

Near-net-shaped part after 3D printing. [Image: GEFERTEC]

In order to investigate the influence of the process gas and the oxygen percentage on 3DMP technology, which combines arc welding with CAD data of metal parts, GEFERTEC GmbH and Linde AG have entered into a joint research project. The two already work closely together – Linde, which is part of the larger Linde Group, uses its worldwide distribution network to supply process gases for 3D printing (especially DMLS/metal 3D printing/LPBF), while GEFERTEC brings its arc machines, which use wire as the starting material to create near-net-shaped parts in layers; conventional milling can be used later to further machine the part after 3D printing is complete.

The 3D printing for this joint project will take place at fellow research partner Fraunhofer IGCV‘s additive manufacturing laboratory, where GEFERTEC will install one of its 3D printers. The last research partner is MT Aerospace AG, which will perform mechanical tests on the 3D printed parts.

Purdue University and USC Researchers Developing New AI Technology

In another joint project, researchers from Purdue University and the University of Southern California (USC) are working to develop new artificial intelligence technology that could potentially use machine learning to enable aircraft parts to fit together more precisely, which means that assembly time can be reduced. The work speaks to a significant challenge in the current AM industry – individual 3D printed parts need a high level of both precision and reproducibility, and the joint team’s AI technology allows users to run software components in their current local network, exposing an API. Then, the software will use machine learning to analyze the product data and build plans to 3D print the specific parts more accurately.

“We’re really taking a giant leap and working on the future of manufacturing. We have developed automated machine learning technology to help improve additive manufacturing. This kind of innovation is heading on the path to essentially allowing anyone to be a manufacturer,” said Arman Sabbaghi, an assistant professor of statistics in Purdue’s College of Science.

“This has applications for many industries, such as aerospace, where exact geometric dimensions are crucial to ensure reliability and safety. This has been the first time where I’ve been able to see my statistical work really make a difference and it’s the most incredible feeling in the world.”

Both 3D Printing and AI are very “hot” right now. Outside of the hype there are many ways that machine learning could be very beneficial for 3D printing in coming years in part prediction, melt pool monitoring and prediction, fault analysis and in layer QA. Purdue’s technology could be a possible step forward to “Intelligent CAD” that does much of the calculation, analysis and part generation for you.

Finalists Announced for Design for Additive Manufacturing Challenge

[Image: Additive Industries]

Additive Industries has announced the finalists for its Additive World Design for Additive Manufacturing Challenge, a yearly competition where contestants redesign an existing, conventionally manufactured part of a machine or product with 3D printing, taking care to use the technology’s unique design capabilities, like custom elements and thin walls. This year, over 121 students and professionals entered the contest, and three finalists were chosen in each category, with two honorable mentions – the Unibody Hydraulic System by from Italy’s Aidro Hydraulics & 3D Printing and the Contirod-Düse from Nina Uppenkam, SMS Group GmbH – in the professional category.

“The redesigns submitted from all over the world and across different fields like automotive, aerospace, medical, tooling, and high tech, demonstrated how product designs can be improved when the freedom of additive manufacturing is applied,” said Daan Kersten, CEO of Additive Industries. “This year again we saw major focus on the elimination of conventional manufacturing difficulties, minimization of assembly and lowering logistical costs. There are also interesting potential business cases within both categories.”

The finalist designs are listed below, and can be seen in the image above, left to right, top to bottom:

  • “Hyper-performance suspension upright” from Revannth Narmatha Murugesan, Carbon Performance Limited (United Kingdom, professional)
  • “Cutting dough knife” from Jaap Bulsink, K3D (The Netherlands, professional)
  • “Cold Finger” from Kartheek Raghu, Wipro3D (India, professional)
  • “Brake Caliper” from Nanyang Technological University team (Singapore, student)
  • “Cubesat Propellant Tank” from Abraham Mathew, the McMaster University (Canada, student)
  • “Twin Spark Connecting Rod” from Obasogie Okpamen, the Landmark University (Nigeria, student)

Marines 3D Printed Repair Part 

US Marine Corps Lance Cpl. Tracey Taylor, a computer technician with 7th Communications Battalion, aboard Marine Corps Base Camp Hansen in Okinawa, Japan, is one of the Marines that utilize 3D printing technology to expand capabilities within the unit. [Photo: US Marine Corps Cpl. George Melendez]

To save time by moving past the lengthy requisitioning process, 3D printing was used at Marine Corps Base Hawaii, Kaneohe Bay, to create a repair part that would help fix a critical component to increase unit readiness. This winter, Support Company, Combat Logistics Battalion (CLB) 3 fabricated the part for the Electronic Maintenance (EM) Platoon, 3rd Radion Battalion, and both EM technicians and members of CLB-3 worked together to design, develop, and 3D print the part, then repaired the component, within just one month, after having spent almost a year trying to get around delays to fix it.

US Marine Cpl. Anthony Farrington, designer, CLB-3, said that it took about three hours to design the replacement part prototype, and an average between five to six hours to 3D print it, before it was used to restore the unit to full capability.

“With the use of 3D printing, Marines are empowered to create solutions to immediate and imminent challenges through additive manufacturing innovation,” said subject matter expert US Marine Chief Warrant Officer 3 Waldo Buitrago, CLB-3.

“We need to embrace 3D printing and encourage our Marines to express their creativity, which in turn, could lead to solutions in garrison and combat such as in this case study.”

3D Printed Helicopter Blade Mold

Thermwood and Bell recently worked together to create a 3D printed tool, but not just any 3D printed tool. Thermwood believes that the 3D printed helicopter blade mold is the largest ever 3D printed autoclave-capable tool. Bell, frustrated with expensive tooling that took a long lead time, reached out to Thermwood for help, and the company suggested its LSAM system, with new 60 mm melt core technology. Bell then provided Thermwood with a 20-foot-long, 17-inch-high, 14-inch-wide closed cavity blade mold, and upon receiving both the model and Bell’s tooling requirements, Thermwood began printing the tool with Techmer PM’s 25% carbon fiber reinforced PESU material (formulated specifically for its LSAM additive printing) in a continuous run. The new melt core can achieve a high print rate, even when processing high temperature material, which was great news for Bell.

Glenn Isbell, Vice President of Rapid Prototyping and Manufacturing Innovation at Bell, said, “Thermwood’s aggressive approach to pushing the boundaries and limitations of traditional 3D printing and machining is exactly what we were looking for.”

The final bond tool was able to maintain the vacuum standards required by Bell for autoclave processing right off the printer, without needing a seal coating. Thermwood will soon 3D print the second half of the blade mold, and both teams will complete further testing on PESU 3D printed molds for the purpose of continued innovation.

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3D Printing News Briefs: February 6, 2018

We’re talking about business, training, and events on today’s 3D Printing News Briefs. The first European 3D printing incubator will soon be inaugurated in Barcelona, and 3devo is launching training workshops about desktop filament extrusion. nScrypt’s Director of 3D Printing and a surgeon from Belfast will be presenting at upcoming events, and Arburg will display a complete turnkey system at an Italian trade fair. Finally, because we celebrate all accomplishments in our industry, we’re sharing some good news about a Xometry employee.

3D Factory Incubator Inauguration

This coming Monday, February 11th, the inauguration of the first European incubator of 3D printing – 3D Factory Incubator – will take place in Barcelona. The Minister of Science, Innovation and Universities, Pedro Duque, will chair the inauguration’s opening act. This High-Tech Business Incubator, a project led by Fundación LEITAT and El Consorci de Zona Franca de Barcelona (CZFB), is working to promote the adoption of 3D printing by creating a space to incubate related SMEs and micro-SMEs.

The 600 sqm incubator space is located at CZFB’s headquarters, and will include training areas, offices, meeting rooms, laboratories, and co-working zones, in addition to a variety of services. The inauguration will begin promptly at 11 am.

3devo Launching Training Workshops

Dutch technology company 3devo, which creates desktop-based material development and recycling solutions such as SHR3D IT, is launching a series of hands-on training workshops all about desktop filament extrusion for professionals, which will be branded as DevoTraining. The workshops will be held at 3devo’s Utrecht headquarters, and participants can choose one of three programs: a basic, 4-hour module for €499, a 1-day intermediate workshop for €899, and a 2-day advanced level course for €1549.

“The demand for unique 3d printing materials is ever-growing, which requires new knowledge on how to process it,” said Tim Wesselink, the CEO of 3devo. “With DevoTraining, we offer the answers to those innovators who seek to take matters into their own hands. Giving them complete guidance to create and customize their own filament – on demand.”

DevoTraining will be officially released next Tuesday, February 12th.

nScrypt Discussing 3D Printed Munitions and Other DoD Applications

Orlando, Florida-based nScrypt, which manufactures micro-dispensing and 3D printing systems, announced the release of its hybrid Factory in a Tool (FiT) integrated system for Direct Digital Manufacturing in October. nScrypt’s Director of 3D Printing, Larry (LJ) R. Holmes, Jr., is in charge of directing the company’s market participation for industrial-level 3D printing hardware, including its work with the US Department of Defense (DoD). This week, Holmes will speak about nScrypt’s 3D printed munitions, as well as its other DoD applications, on the “AM Innovation Panel: Developing the Next Generation of 3D Printing and Processes in Support of the Warfighter” in Tampa at the Military Additive Manufacturing Summit & Technology Showcase.

“Our FiT platform is ideal for DoD’s 3D printing applications because it does next generation Direct Digital Manufacturing, which means no retooling to build a product or to change from printing one product to another. Just change the CAD file. Our FiT’s pick and place tool head adds actives to the prints, making them electrically functional if needed. We just delivered a Factory in a Tool to the Army’s Redstone Arsenal. It has one full meter of travel in the XY plane,” Holmes said.

“nScrypt’s goal is to disrupt how manufacturing happens. Munitions printed on-demand, where and when they are needed; a ruggedized 3D printer for use in forward deployed locations; and printed electronics, like conformal Active Phased Array Antennas for improved performance at lower cost, are a few of the examples of capabilities currently being transitioned from nScrypt to the DoD and the global manufacturing industrial base.”

SXSW 3D Printing Presentation About 3D Printed Kidney Model

SXSW 2019 begins next month in Texas, and in addition to the many other innovations on display at the event, Dr. Tim Brown, Consultant Transplant Surgeon at Belfast City Hospital, will share his experience of using 3D printing to successfully perform a first of its kind, life-saving operation during a presentation titled “Tumours, Transplants and Technology: AI for Life.” His patient needed a life-saving kidney donation, and while her father was willing to donate, his kidney had a tumor on it. Together with UK medical 3D printing company axial3D and Digital Catapult, Dr. Brown used a 3D printed kidney model to safely complete the transplant surgery and save his patient’s life.

“As the cyst was buried deep within the renal cortex and therefore invisible on the back bench, a replica 3D model was used for preoperative planning and intra-operative localization of the lesion,” explained Dr. Brown. “It’s difficult to underestimate how valuable this strategy was in terms of preoperative planning and achieving successful clearance of the lesion.”

axial3D won the Healthcare Application Award at the 2018 TCT Awards for creating the 3D printed model, and the company’s CEO Daniel Crawford and Operations Manager Cathy Coomber will join Dr. Brown for a panel discussion at SXSW, along with Nigel McAlpine, Immersive Technology Lead at Digital Catapult. The session will take place at SXSW on March 12th, at the JW Marriott Salon FG.

Arburg Exhibiting at MECSPE 2019

Arburg Allrounder Freeformer

At next month’s MECSPE 2019 trade fair in Italy, German machine construction company Arburg will be focusing on 3D printing, automation, and digitalization. The company will be displaying a complex turnkey system, built around a Freeformer 200-3X industrial AM system and a hydraulic Allrounder 370 S; both the Freeformer and Allrounder are networked live with the company’s ALS host computer system. In addition to displaying the system at the trade fair, Arburg will also have experts presenting their outlook on the digital future of plastics processing at Stand F49 in Hall 6.

“MECSPE 2019 is the most important trade fair for the manufacturing industry in Italy and, with its focus on Industry 4.0 and automation, it is an ideal match for Arburg. We are not only a machine manufacturer and expert in injection moulding, but we also have our own MES, our own controllers, automation technology and the Freeformer for industrial additive manufacturing as part of our product portfolio,” said Raffaele Abbruzzetti, the new Managing Director of Arburg Srl. “With more than 30 years of experience in networked and flexibly automated production, we offer our customers everything they need in the era of digitalisation to increase their added value, production efficiency and process reliability – from the smart machine to the smart factory and smart services. We will present examples of all of this at MECSPE.”

Xometry Employee Wins Game Show

This last News Brief has nothing to do with 3D printing itself, but rather an unrelated, but still incredible, accomplishment from one of the industry’s own. On Thursday, January 24th, employees from on-demand manufacturing and 3D printing service provider Xometry gathered to watch one of their colleagues – marketer Aaron Lichtig – compete, and eventually win big, on the popular Jeopardy! game show that night.

Lichtig started off at a steady pace, competing against returning champion and astrophysicist Rachel Paterno-Mahler and sales manager Nancy Rohlen, and was leading the pack with a final score of $12,400 by the end of the Double Jeopardy round. He squared off against Rohlen during Final Jeopardy with the clue, “He was the first U.K. prime minister born after Elizabeth II became queen.” While both correctly guessed the answer as Tony Blair, Lichtig’s steep lead made him the winner that night. Congratulations from your friends at 3DPrint.com!

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Titomic Shares News About 3D Printing Executives and $1.8 Million MoU to Make 3D Printed Soldier Systems

Australian metal 3D printing company Titomic, known for its innovative Titomic Kinetic Fusion (TKF) process, has plenty of big news to share this week. First, CEO Gilbert Michaca, who was responsible for implementing a series of governance and operational structures to support Titomic’s next growth phase, has resigned from the company.

“I have enjoyed my time with Titomic and the additive manufacturing sector, but I am moving to pursue other commercial opportunities more aligned with my interests,” said Michaca. “I look forward to witnessing Titomic’s growth and prosperity in the future.”

Jeffrey Lang

In addition to Michaca’s resignation, Titomic announced that its founder and former Interim CEO Jeffrey Lang, who led the company through its IPO, and the establishment of its cold spray facility in Melbourne, has now been appointed as the Managing Director, effective immediately.

“Following our whirlwind IPO and unprecedented growth phase, the Titomic team has delivered a lot in a very short period of time,” said Titomic Chairman Philip Vafiadis. “With Jeff stepping into his new role as the Company’s Managing Director we are excited that his significant knowledge and networks across industry sectors, his deep understanding of the technology, his experience, his passion and his understanding of investor needs bodes well for future growth and shareholder value.”

Moving on from news about its executives, Titomic has just signed a $1.8 million, year-long MoU with fellow Australian company TAUV Proprietary Limited (TAUV), which integrates electronic technologies into solider protection for the purposes of improving safety and performance. Together, the two will begin an exclusive defense program for Titomic to manufacture soldier systems, unmanned aerial vehicles (UAV), and soldier sensors for TAUV.

Recently, TAUV completed a successful launch of the first ruggedized titanium tactical UAV at Land Forces 2018, which was manufactured by Titomic and caused great excitement in both the additive manufacturing and defense industries. This launch was Phase 1 of the partnership between the two companies, and the MoU was signed after the prototype drone launch. TAUV and Titomic agreed to a two-phase extension to their existing relationship, so that TAUV can license the TKF technology, patented in both the US and Australia, in order to make next-generation soldier systems.

According to Research and Markets, “The soldier systems market is projected to grow from USD$9.78 billion in 2018 to USD$14 billion by 2023, at a CAGR of 7.65%.”

TAUV Tactical Unmanned Aerial Vehicle at Land Forces, 2018.

TAUV worked hard to secure exclusivity with Titomic for the manufacture of its UAV and other soldier system products, like body armor and helmets. Under Phase II of the partnership, Titomic will deliver a feasibility report, which outlines mechanical properties, performance parameters, and product cost advantages of its technology, to TAUV. TAUV must outline the Specific Products on or before November 30, at a total Phase cost of $300,000, in order to execute Phase II and maintain exclusivity.

“This MoU with TAUV provides the first significant revenue for Titomic,” said Lang. “The granting of an exclusive license to TAUV for the production of solider systems further validates Titomic’s licensed CSIRO patents as a viable additive manufacturing process that enables Australian companies to manufacture cutting-edge products with competitive advantages for the global market.”

For Phase III, Titomic will design and engineer a manufacturing process for TAUV’s next-generation soldier system for up to five products, at a cost of $300,000 each, to add up to a total revenue of up to $1.5 million. Once the production and evaluation trials in this phase have been completed, the two companies will finalize product licenses so that TAUV can use the automated TKF production line systems to fabricate soldier system products…with continuing royalty payments going to Titomic for the use of its technology.

TKF uses a process similar to cold spray to build up titanium parts layer by layer, rather than simply coating a surface, and has no limits in terms of shape and size. The technology has unique additive manufacturing capabilities to offer to defense organizations for the production of lightweight, next-generation, high-performance products.

“The solider system products produced by Titomic’s TKF process will enhance the offering to defence and law enforcement agencies through improved strength, functionality and capability,” said TAUV Director Nathan Kalisch. “A new ruggedised UAV will be capable of deployment in dangerous, live combat situations to perform some of the direct combat roles we want to remove military personnel from, heightening their security.”

L-R: Titomic CTO Jeff Lang, TAUV Founder Nathan Kalisch, Titomic CEO Gilbert Michaca

This continuing partnership came about as the result from an increasing demand around the world for innovative new defense products. According to Variant Market Research, the market for combat helmets is estimated to grow to $3 billion by the year 2024, while Grand View Research states estimates that by the same year, the body armor market will be valued at $4 billion.

In the future, TAUV will be working closely with Force Ordnance to provide product innovation and advanced manufacturing solutions to some of the largest defense product manufacturers in the world.

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[Images: Titomic]

US Air Force Base in Utah Creating 3D Printed Replacement Parts for F-35 Fighter Jets

The US military has not shied away from implementing modern manufacturing methods such as 3D printing, but has actually embraced the technology. In fact, the US Air Force has used 3D printing for multiple projects, including components for aircraft and fighter jets, such as the F-35. This is what’s known as a next-generation fighter, and the 388th Maintenance Group of the Hill Air Force Base in Utah recently began 3D printing specific replacement parts for the F-35. Base officials are hoping that the technology will help to lower costs and increase availability.

Many branches of the military have turned to 3D printing to make replacement parts for those very same reasons.

“We’re always driving for speed, safety and quality. But cost-effectiveness is also a priority,” said 388th MG commander Col. Michael Miles. “This new tech has great cost-avoidance potential and provides rapid repair capabilities.”

Tech Sgt. Scott Mathews, assistant manager of the 388th Maintenance Group’s Air Force Repair and Enhancement program, makes adjustments to a 3-D printer the unit is experimenting with to create pieces and parts faster and more cost-effectively. [Image: Todd Cromar]

According to Tech. Sgt. Scott Mathews, assistant manager of the 388th MG’s Air Force Repair and Enhancement Program, early returns are showing that when his shop gets in damaged parts that are able to be reproduced through 3D printing, they are then able to be introduced into the supply chain with greater speed and at lower cost.

Tech. Sgt. Mathews explained, “It’s much more cost effective for the Air Force than buying new parts.”

One of the first items the team at the 388th MG created was a small-scale replica of the F-35 fighter jet. But now they’ve moved onto 3D printing simple plastic replacement parts, such as cable splitters, fasteners, grommets, housing boxes, and wiring harnesses. Tech. Sgt. Mathews said that many areas of the shop have figured out how to make the 3D printing easier to work with by “getting away from a lot of fancy metals and getting into composites and plastics.”

F-35 [Image: Lockheed Martin]

However, the technology is still young in the shop at Hill AFB, and the unit’s airmen are using trial and error to refine things, including using computer software to make their own in-house designs. There are even signs that they could manufacture more complex parts out of stronger materials in-house one day.

“There’s one printer (where) you can print with aluminum. That opens up a whole new world of opportunities,” said Tech Sgt. Matthews. “When you look at all of the different parts we could manufacture … it just boggles the mind, the things we could (make) on base. It’s just insane.”

The first two F-35 fighter jets arrived at Hill AFB in September of 2015. But, by the end of 2019, there will be three whole fighter squadrons, made up of a total of 78 jets, on the base. The active duty 388th Fighter Wing and the reserve 419th both fly and maintain the jets, while the Ogden Air Logistics Complex on base performs maintenance on all of the F-35s. Hopefully, 3D printing can soon be used to help with all of this maintenance.

Tech Sgt. Matthews said, “There’s a sense of pride knowing you played at least a minuscule role of getting them airborne.”

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[Source: Standard Examiner]