Additive Flight Solutions Awarded AS9100D Certification for Commercial Aircraft 3D Printing

With increasingly stringent standards and regulations governing the aircraft industry, MRO providers must obtain the latest certifications in order to serve their customers, as well as to ensure compliance within their organizations and supply chains. The AS9100 certification standard governs quality management systems in the aerospace industry, and its latest revision AS9100D, updated or changed more than 98% of the previous standard. The revision had broad implications for MRO providers, and introduced a particularly strong focus on accountability, to ensure strict safety protocols and to introduce preventive risk-based thinking, and measures to prevent the use of counterfeit products.

Image courtesy of Additive Flight Solutions.

In a boost to the Singapore-based company’s growing reputation as a provider of additive manufacturing part solutions for aerospace maintenance, repair and overhaul (MRO), Additive Flight Solutions (AFS) has received the AS9100D Certification. It is also now registered with the International Aerospace Quality Group (IAQG), the global body that governs quality management within the worldwide supply chain of the aerospace industry.

This is all the more relevant as additive manufacturing solutions, such as those from AFS, increasingly transform or complement the traditional MRO business in providing parts and services that meet the quality requirements for end-use in aircrafts. A joint venture between major Asia-Pacific MRO provider, SIA Engineering Company (SIAEC), and Stratasys, AFS brings Stratasys’ additive manufacturing expertise and solutions to more than 80 international carriers and aerospace OEMs through SIAEC. AFS provides AM solutions for aerospace certification (such as the Aircraft Interiors Certification Solution), prototyping, manufacturing aids and tooling, and production parts using thermoplastics.

Composite Tooling. Image courtesy of Additive Flight Solutions

In particular, it supplies industry grade parts and services for airplane cabin interiors (sanitizer holders for example) to local and global manufacturers. The AM parts are primarily used as replacements for interior cabin parts, which are low volume, and can often be obsolescent. Regarding the certification, Stefan Roeding, DGM, AFS said,

“From individual part weight reduction to a more comfortable layout and design, the future of aircraft interiors is set to take off in innovative ways. Apart from being a competitive advantage, achieving the AS9100D is a significant milestone for AFS and our parent companies. This certification validates our commitment to drive the development of aerospace applications and deliver reliable and precisely engineered solutions. It gives us immense pride in attaining this globally recognized mark of excellence.”

With the AS9100D certification for an AM part provider, aerospace manufacturers can enable partnerships and strengthen confidence in collaborating with AFS to advance next-generation aerospace MRO solutions. AM parts have proven their improved material properties, to deliver better performance, efficiency and flexibility in aerospace manufacturing, design, and supply chains. These parts must also meet requirements from international organizations such as the European Union Aviation Safety Agency (EASA).

                                                                                                                Image courtesy of Additive Flight Solutions

In other partnerships to advance AM in aerospace MRO, Oerlikon is working jointly with Lufthansa Technik to accelerate AM in MRO applications, EOS is doing the same with Etihad Airways Engineering for cabin parts, and so is Pratt & Whitney working with ST Engineering for aero-engine components. Similarly, Air New Zealand is working with Arcam EBM to produce metal AM parts for aircraft interiors, MRO tooling and product development. Premium Aerotec and Materialise have partnered with Airbus to supply metal and polymer parts respectively. Stratasys has also partnered with Marshall Aerospace and Defense Group to 3D print flight-ready parts as well as ground-running equipment.

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Russia Successfully Tests 3D Printed Engine

Russia continues to venture into additive manufacturing for critical applications, just releasing the successful results of a flight test for their 3D printed MGTD-20 Gas Turbine Engine. The Russian Foundation for Advanced Research Projects in the defense Industry relayed this new information to Russian state-controlled news agency, Sputnik:

“Russia has for the first time conducted flight tests of the MGTD-20 gas turbine engine made by 3D-printing,” the statement said.

Testing (resulting in a successful landing) was held at the Kazanbash aviation center in Tatarstan, about 500 miles east of Moscow—following successful evaluation also of gas turbine engines 3D printed last year. The device passed altitudes of 170 meters during testing, with a maximum ground speed of 154 kilometers per hour. According to the Russian Foundation for Advanced Research Projects, engine speed was noted at 101,600 rpm, while was working speed was 58,000 rpm.

Exemplifying the benefits of 3D printing, the Russian engineers have reported that they were able to decrease production time exponentially; in fact, they are now not only manufacturing the components for aircraft 20 times faster, but they have also been able to cut the cost factor significantly.

These improvements fall in line with many of the advantages of using what most may consider to be a new and progressive technology; however, organizations like NASA have known about—and have been employing 3D printing—for several decades. While the technology was originally used by engineers for rapid prototyping of parts then produced via conventional manufacturing, more commonly now high-performance, strong, lightweight, and functional components are being 3D printed.

This is true for numerous other critical applications to include medical, aerospace, automotive, and construction. In some cases, strides already made within 3D printing have transformed industries like medicine and aerospace, while yet others like construction are still slowly evolving with some promises from developers continuing to be proven overinflated.

Manufacturing of the aircraft is expected in 2021-2022. The engines are 3D printed with heat-resistant aluminum alloys meant for serious industrial use, offering a 22-kilogram-force thrust. The project was developed in coordination with the Fund for Advanced Research and the Federal State Unitary Enterprise “VIAM” State Scientific Center of the Russian Federation with the participation of JSC NPO OKB im. M.P. Simonov.

The Russians have certainly not been devoid of headlines regarding 3D printing, including their latest news at the International Space Station as Russian cosmonaut Oleg Kononenko bioprinted cartilage to advance regenerative medicine in space while in zero gravity conditions. In other projects, Russian researchers have experimented with 3D printing titanium for medical implants, and have also ventured into the area of construction of homes that can be manufactured onsite, and quickly so.

In the US, 3D printing for rocket engines has continued, with dynamic projects continue to evolve via NASA—from new methods to fabricate complex rocket engine nozzles to collaborating with businesses like Aerojet Rocketdyne for production of RS-25 engine rockets, while other companies like Launcher and AMCM have been behind the successful production of a large single-part 3D printed rocket.

[Sources: Russian Foundation for Advanced Research Projects; Affairs Cloud; Big News Network / Image: Big News Network]

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Markforged Metal 3D Printing Replaces Obsolete Part for Legacy Race Car

Founded in 2013 by Greg Mark, Massachusetts-headquartered Markforged quickly became a powerful presence in the 3D printing industry, first with carbon fiber reinforced 3D printing and then developing a novel metal 3D printing technology.

With a range of end-to-end processing systems, Markforged offers its customers access to the boldest advantages in additive manufacturing—not only through rapid prototyping but also rapid speed in the fabrication of high-performance parts. Past the initial investment, industrialists are able to see substantial savings, along with a new ability to innovate upon casting aside the restrictions of older technology. These benefits drew the attention of Tecron, a European company known for its manufacturing and engineering services in the automotive industry.

In a recent case study, the Markforged team details how metal AM processes improved the production of high-performance parts needed for the vintage race cars Tecron has been working on lately. Metal 3D printing offered the opportunity for Tecron to make a shift, especially in working with one of their most important clients, Škoda Motor, to streamline the production of an original, discontinued racecar carburetor.

Tecron’s collaboration with Škoda Motor exemplifies one of the most exciting benefits in 3D printing—offering the ability to create parts that may have become obsolete and are nearly impossible to find. We have followed other projects too within automotive and railways applications, with 3D scanning of original parts allowing for better rebuilding and maintenance.

In the case of the missing design for the carburetor, the original die used in traditional die-casting methods was lost long ago. The Tecron design team not only made an affordable copy of the initial race-car component, but they also modified the structure for better optimization.

Tecron replica carburetor

In another study, Czech Aerospace Research Centre (VZLU) partnered with Tecron for prototyping and testing new parts. Engineers were tasked with creating a new wing design and challenged with finding a method that was not cost-prohibitive. Prototyping can require extensive (and expensive) measures for applications like aerospace, and VZLU realized the need for different, advanced technology in creating complex models like their innovative nozzle design.

“The narrow slit in the design improves overall wing performance, and was crucial to the success of the process. Deconstructing the design into several more manageable parts would have a negative impact on performance,” stated the Markforged case study.

The use of electrical discharge manufacturing (EDM) was another possible choice, but was not cost-effective and would have taken much longer than with metal 3D printing. In using the Metal X by Markforged, the engineers were able to complete their highly customized design, quickly and affordably.

After analyzing over 100 additive use cases, Markforged discovered that industrial users are concerned with the following:

  • Accessibility
  • Design freedom
  • Physical strength and durability
  • Reliability

Data was compiled from the 2020 Additive Trends Report by Markforged, also showing that 46 percent of companies expect to be using additive manufacturing within the next two years. Download the study here.

[Source / Images: Markforged]

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3D Printing Webinar and Virtual Event Roundup, July 19, 2020

A variety of topics will be covered in this week’s webinar and virtual event roundup, including additive manufacturing in aerospace, CAMWorks, product management, post-processing, and more. Read on to learn more about, and register for, these online opportunities.

AM in Aerospace Virtual Panel

On Tuesday, July 21st, Women in 3D Printing (Wi3DP) will host the third event, “Additive Manufacturing for Aerospace”, in its virtual panel series. Sponsored by AlphaSTAR and Link3D, the panel will focus on how AM is used in the aerospace industry. Moderated by AM-Cubed founder Kristin Mulherin, the speakers are Anna Tomzynska, Director and Additive Manufacturing Chief Engineer for Boeing; Deb Whitis, GE Aviation Chief Engineer; and Eliana Fu, Senior Engineer, Additive Technologies, at Relativity Space.

Pre-registration will begin at 11 am EST, with a welcome speech at 11:25. The hour-long panel will begin at 11:30, with plenty of time for live Q&A, and there will be a virtual networking reception at 12:30. Register for the virtual panel here.

3DEO Webinar – Why I Switched From CNC Machining

Also on July 21st, metal 3D printing company 3DEO is hosting a live webinar, entitled “Why I Switched From CNC Machining: An Engineer’s Perspective on Transitioning to Metal 3D Printing.” The webinar, which starts at 1 pm EST, will feature 3DEO Applications Engineer Julien Cohen, who will explain the major differences between metal 3D printing and CNC machining. The following topics will be covered:

  • Compare CNC machining and 3DEO’s proprietary metal 3D printing process

  • Understand the value metal 3D printing offers engineers in design and flexibility

  • Learn about the pros and cons of each process and when metal 3D printing makes sense

  • Discover three real-world case studies of 3DEO winning versus CNC machining

  • See 3DEO’s process for going from first articles to production

You can register for the webinar on 3DEO’s website.

Free CAMWorks Webinar Series

To make sure professionals in the CAM industry have easy access to educational and training materials during the COVID-19 crisis, a free CAMWorks webinar series has been launched. Each session will give attendees the opportunity to increase their CAM skills, learning about more advanced features that can help maintain business operations. SOLIDWORKS CAM and CAMWorks: Getting Started” is on Tuesday, July 21st, at 10:30 am EST, and will be a training session on using the integrated CNC programming system SOLIDWORKS CAM Standard. It will also provide an introduction to the Technology Database (TechDB), which can automate the CNC programming process. “SOLIDWORKS CAM for Designers: A Path to Better Designs” will also take place on July 21st, at 2 pm EST, and will focus on how to use SOLIDWORKS CAM to reduce cost, improve design, and make it easier to manufacture parts.

You’ll need to attend the “Getting Started” webinar before attending “SOLIDWORKS CAM and CAMWorks: Getting Started with the TechDB” on Thursday, July 23rd at 10:30 am EST. This is a more in-depth training session for using the TechDB included in SOLIDWORKS CAM and CAMWorks. The final webinar in the series is “The Future of Manufacturing in the COVID Era,” also held on July 23rd, at 2 pm EST. This session will help attendees learn how to automate part programming to stay productive and competitive during and after the pandemic.

Protolabs Webinar: HP’s Multi Jet Fusion

On Wednesday, July 22nd, at 2 pm EST, Protolabs will be hosting a webinar with HP, called “Tips and Tricks to Leverage Multi Jet Fusion in your Product Development Cycle.” One of the company’s Applications Engineers, Joe Cretella, and Brent Ewald, HP’s Solution Architect, will discuss design tips that result in good MJF parts, how to implement the technology, and where MJF fits within additive and subtractive manufacturing.

This webinar will help attendees understand how the HP Multi Jet Fusion technology 3D printing process can be leveraged in various stages of the product development lifecycle. The experts at HP and Protolabs have teamed up to give you key insights into Multi Jet Fusion materials, processing capabilities, and part quality. Whether the attendee is new to additive manufacturing or evaluating Multi Jet Fusion for their production project, this presentation will help identify when the technology provides the most value and what to consider when manufacturing Multi Jet Fusion parts.”

Register for the webinar here.

Dassault Systèmes on Project Management Solutions

At 10 am EST on Thursday, July 23rd, Dassault Systèmes will hold a live webinar,”Discover How to Deliver Projects on Time and Under Budget, a Real-time Online Experience,” all about collaborating with integrated project management solutions connected to 3D engineering data in order to drive project success. Dassault speakers Maximilian Behre, the Online Industry Business Consultant Director, and 3DS Industry Process Consultants Siddharth Sharma and Alessandro Tolio, will discuss project management challenges, shortening the design cycle through the 3DEXPERIENCE platform, provide a demonstration of Project Management on the cloud, and answer questions.

“Whether you are managing big programs that involve hundreds of people or are leading a smaller project, an easy to use integrated project management solution will help you to seamlessly collaborate across all disciplines with any stakeholder. Connect the dots between Marketing, Engineering to Manufacturing and customer services.”

Register here.

KEX Knowledge Exchange on Post-Processing

Finally, former Fraunhofer IPT spinoff KEX Knowledge Exchange AG is holding its second webinar on its KEX.net web platform, “Online Seminar Post-Processing for Additive Manufacturing,” on Thursday, July 23rd. Lea Eilert, the project and technology manager for the ACAM Aachen Center for Additive Manufacturing, will teach attendees about typical heat treatment for AM materials, the necessity of post-processing for 3D printed components, and various post-machining and surface finishing methods.

Register for the webinar here. In addition, Eilert will also present the third KEX webinar on August 6th, entitled “Market, Costs & Innovation.”

Will you attend any of these events and webinars, or have news to share about future ones? Let us know! 

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Joyson Safety 3D Prints Functional Airbag Housing Using Windform

Joyson Safety Systems, a leading provider of mobility safety components, systems and technology, recently developed its first functional 3D printed prototype of a Driver Air Bag (DAB) housing, using selective laser sintering (SLS) and Windform composite material from CRP Technology.

Image courtesy CRP Technology

Joyson Safety Systems already has a history of pioneering innovation in mobility safety solutions, such as airbags, seatbelts, safety electronics and more, for automotive and non-automotive markets. Worth noting is the fact that it was the first manufacturer to supply leading OEMs in North America and Europe with steering wheels with Hands on Detection (HOD) for autonomous driving. In this instance, the company’s Core Innovations team looked to quickly develop prototypes for its airbag housing and turned to additive manufacturing to explore new processes and materials.

Image courtesy CRP Technology

Traditionally, the airbag housing is produced using injection molding made up of a material that is polyamide with 40% glass fiber reinforcement, PA6-GF40. The DAB system, which needs to deploy in just 30-50 milliseconds to prevent injury to the driver, consists of the inflator, airbag cushion, cover and housing attached to the steering wheel. The performance of this system is essential, as a critical safety component of the vehicle that needs to have enough strength, impact resistance, and stability under heat and other diverse environmental conditions. Samer Ziadeh and Daniel Alt from the Core Innovations team explain the requirements for the DAB,

“It is to withstand a high amount of dynamic loads in addition to holding the inflator and the airbag cushion fixed in location during and after the deployment of the airbag system. This load is developed due to the pressure required to inflate the airbag, as a result the large stresses will directly be applied on the airbag system and more particularly on the DAB housing. The test procedures are normally conducted within a various range of temperatures between -35°C and 85°C.”

Image courtesy CRP Technology

In looking for the right material for the DAB, the team found CRP Technology’s patented Windform range of high performance SLS materials more than suitable for their requirements:

“…after running some market analysis in order to find out the most suitable material and process that could deliver the required performance, we came across the Windform TOP-LINE family of composite material and, specifically, the Windform SP. Windform SP brought our attention to the fact that it’s a material produced from polyamide PA grades, reinforced with Carbon fiber or fiber-glass, as a powder form material, and it has almost the required and even better performance for our application.”

Windform has emerged as a high performing SLS material which has been applied in sectors such as motorsports, as with Mercedes AMG Petronas, automotive, and aerospace, as with NASA. Windform materials not only meet the stringent requirements for use in aerospace or motorsports, but can also be CNC machined or post-processed with tooling equipment. CRP has become a leader in high-performance AM materials for SLS with Windform, applying its expertise in a range of proven applications from medical to UAVs, satellites to electric motorbikes.

Image courtesy CRP Technology

This application is a first for Joyson Safety Systems in producing, in a short period, a functional prototype of a DAB housing using SLS with composite materials.

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Farsoon Releases Flight 252 High Temperature 3D Printing Platform

Following the progress of many manufacturers over the years, it is clear that users around the globe are not left wanting for the new technology and new resources required to keep reaching for the stars while innovating. China’s Farsoon Technologies (with headquarters also in the US and Germany) is a dynamic example of this system—within an industry worth billions—continuing to serve customers with new printers, platforms, and materials within the additive manufacturing space.

Now, Farsoon moves further forward with its Flight Technology (initially unveiled at TCT Asia 2019) for the compact Flight 252P platform. Two new plastic powders are also being released, and Farsoon claims they will not only improve performance in parts, but also savings on the bottom line. With over 25 years in the industry, Farsoon is a pioneer in the plastic laser sintering solutions market and its team expects to continue pushing forward in terms of enhancing efficiency in production, performance, and expansion.

Notably, these new products are being announced at TCT Asia 2020, running from July 8-10. This is the “first physical trade show” the Farsoon team will be attending since the COVID-19 viral pandemic forced show cancellations around the world. Visitors will be able to check out the new platform in person now, finding out more about high-temperature printing, reaching from 220°C (HT) to 280°C (ST). Other features of the new system include better thermal control, improved parameters, and temperature-shielded components.

The 252P is smaller, making it suitable for laboratories as well as onsite for small-scale production. This new platform also provides industrial users with the opportunity to use a wider range of materials. In comparison to typical laser sintering systems, Farsoon also promises that the Flight 252P offers more latitude for developers in terms of materials and applications. Comprehensive processing is offered, and along with a smaller laser spot size (and better laser longevity) comes “greatly increased power.”

The new materials offer the following:

  • PA12 based FS3201PA-F powder for Flight Technology – for applications like auto, electronics, and consumer markets, this advanced formula is meant to offer better durability and reusability.
  • FS2300PA-F polyamide powder is meant to offer users better affordability, faster production, as well as “excellent plasticity.”

Farsoon continues to be known for its advances in additive manufacturing, collaborations with other global leaders, and sales of large installations of hardware.  Are you interested in joining the Farsoon early adopter program? If so, contact globalinfo@farsoon.com for more information.

[Source / Images: Farsoon]

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3D Printing Webinar and Virtual Event Roundup, June 28, 2020

This week is packed full with 3D printing webinars and virtual events, with four taking place Tuesday, and two each on Wednesday and Thursday.  We’ll tell you all about them below!

Digital Manufacturing Investor Day

First up, software provider Dyndrite will be hosting its first ever Digital Manufacturing Investor Day on Tuesday, June 30th, featuring both pre-recorded and live content. Investors and venture capital companies have been invited to hear lightning presentations by hardware and software startups from all around the world, and several industry investment firms will also give panel presentations. The advisors for the inaugural Digital Manufacturing Investor Day are Gradient Ventures, HP Tech Ventures, and The House Fund.

“This virtual event is an initiative to help link startups in the digital manufacturing space to investors in the industry. As supply chains have been recently disrupted and workforces have to remain distanced, so new digital manufacturing technology becomes even more critical as manufacturers figure out how to tackle these challenges.”

Register here.

Additive Manufacturing for Aircraft Interiors 

Also on June 30th, a webinar about 3D printed aerospace applications will take place from 9-10 am EDT. “Additive Manufacturing for Aircraft Interiors – doing the trick for the In-Service Market” will discuss the use of polymer 3D printed parts for future aircraft cabins, how the technology can save money and time, possible new business opportunities for Maintenance Repair and Overhaul Providers (MROs), and what issues still remain, such as certification, investments, and availability of the right raw materials. Stephan Keil, Director Industrialisation for AM Global, will moderate the discussion between panelists Markus Glasser, Senior Vice President EMEA, EOS; Vinu Vijayan, Global Business Development Manager – Aerospace, EOS; Frederic Becel, Design Manager, CVE, Innovation Leader Aircraft Modification Division, Air France; and Karl Bock, Principal Design Engineer, Aircraft Modification Team, P21J Design Organisation, Lufthansa Technik.

“A wide spreading of AM manufacturing also has the potential to significantly change the supply chain setup of the Aero industry, impacting small and large suppliers, as distributed manufacturing moves closer to becoming a reality. Furthermore, new business models for spare parts and part design data may emerge, along with new services, which brings a need to tackle challenges around IP and regulation.”

Register here.

nScrypt’s Cutting Edge of Digital Manufacturing Webinar

nScrypt is also holding a webinar on the 30th, titled “Pushing the Envelope of Digital Manufacturing.” The first part of the Cutting Edge Digital Manufacturing webinar series will take place at 1 pm ET on the 30th, and the second part will occur at the same time on July 7th. Panelists Mark Mirotznik, PhD, University of Delaware; Jing Wang, PhD, University of South Florida and Oregon State University; Devin MacKenzie, PhD, University of Washington, and Raymond C. Rumpf, PhD, University of Texas at El Paso, will discuss the future of direct digital manufacturing, covering topics like metamaterial use, permeating electronics in structures for control, sensing, and smart features, and going from a CAD file to a final, multimaterial electronic product in one build.

“JOIN YET ANOTHER DISTINGUISHED PANEL for part ONE of an in-depth discussion on the future of direct digital manufacturing by some of the premiere additive manufacturing universities in the country. The projects these universities are working on are solving problems with traditional antennas and printed circuit boards (PCBs).

Register here.

ACCIONA’s Concrete 3D Printing Webinar

The last June 30th webinar will be held by ACCIONA, called “Let’s Talk Concrete 3D Printing.” It will take a multidisciplinary approach when discussing the technology’s use in the value chain, “where Innovation, Academia, Design, Manufacturing and Industry join together for a broad analysis of the technology.

Speakers will be Alaa K. Ashmawy, PhD, P.E. Dean and Professor for the School of Engineering at the American University in Dubai; Sualp Ozel, Senior Product Manager at Autodesk; Fahmi Al Shawwa, the CEO of Immensa Additive Manufacturing; Carlos Egea, Manager 3D Printing, Skill Center at ACCIONA; and Luis Clemente, COO 3D Printing at ACCIONA. The webinar will take place at 8:30 am EST, and attendees can join here.

3D Systems Webinar Featuring VAULT

On Wednesday, July 1st, at 10:30 am EST, 3D Systems will be holding a live webinar, “Advanced Your Engineering and Equip Sales to Win Business with SLA,” featuring VAULT, which manufactures enclosures for tablets in the point-of-sale industry. The company integrated 3D Systems’ SLA technology into its process, and the 45-minute webinar will explain how SLA can be used at every stage of business. VAULT will share customer reactions to quality and service, in addition to the training and on-boarding process, and explain how companies can win new business by providing access to high-quality 3D printed parts.

“Gaining a new client is all about gaining their confidence. No matter how refined your sales pitch, nothing wins trust or business faster than immediately following through on your promises.

“Join our live web event featuring VAULT’s VP of Engineering, Quentin Forbes, to find out how in-house 3D printing with 3D Systems’ stereolithography is helping the company build its reputation and client base.”

Register here.

Webinar for New Metal 3D Printing Material

Also on July 1st, metallurgist expert Aubert & Duval will join Alloyed, formerly known as OxMet Technologies, in hosting a free webinar about ABD-900AM, a new nickel superalloy for metal additive manufacturing. When tested with laser powder bed fusion (LPBF) technology, the high-strength material offered improved manufacturability, as well as high creep and oxidation resistance, compared to common AM alloys. It also features ~99.9% density and is highly crack resistant. Adeline Riou, Global Sales Manager at Aubert & Duval, and Will Dick-Cleland, Additive Manufacturing Engineer at Alloyed, will give an overview of the material’s properties, along with several interesting case studies, during the 30-minute webinar.

“Designed for use at high temperatures up to 900°C / 1650°F, ABD®-900AM has been tailored for AM by Alloyed not just for high mechanical properties, but also for excellent printability. Compared with Ni718, ABD®‑900AM provides a minimum of 30% improvement in yield stress at temperatures >800°C and a creep temperature capability improvement by up to 150 o C – similar to alloy 939 and alloy 738.”

The webinar will begin at 11 am EST, and you can register here.

Stratasys Aerospace Webinar Series Continued

Stratasys will continue its new aerospace webinar series this Thursday, July 2nd, with “Value Proposition of AM to Airlines.” During this hour-long webinar, Chuan Ching Tan, General Manager, Additive Flight Solutions (AFS), will speak about several related topics, including when and where additive manufacturing can make its business case to airlines, use cases – especially regarding aircraft interiors – by AFS to airlines, and other issues to get past in order to speed adoption of the technology.

You’ll have to wake up early if you’re in my time zone – the webinar will take place at 4 am EDT. Register here.

VO Webinar: Coming of Age for Additive Manufacturing

Recently, Viaccess-Orca (VO), a global provider of advanced data solutions and digital content protection, joined the collaborative 3MF Consortium as a Founding Member. Now, it’s presenting a free 45-minute webinar with HP and Autodesk, also active members of the 3MF Consortium, about “Additive Manufacturing’s coming of age: the essential role of data security and standards.” The webinar, also held on July 2nd, will focus on the importance of data security and standards as the closed AM ecosystem moves to a more open future. Dr. Phil Reeves, Managing Director of Reeves Insight Ltd, will facilitate the discussion between speakers Scott White, Distinguished Technologist, 3D Software and Data, HP, Inc.; Martin Weismann, Principal Software Engineer for Autodesk; and Alain Nochimowski, Executive Vice President of Innovation at VO.

Learning objectives of the webinar will include why data standards are so important for the growth and deployment of the technology in the Industry 4.0 supply chain, how 3D CAD and AM hardware vendors can embrace both interoperability and data standards to benefit customers, what the 3D printing industry can learn about analytics, traceability, and data security from more mature industries, and the consortium’s newly released Secure Content specification. At the end, there will be a Question and Answer session, facilitated by Laura Griffiths, Deputy Group Editor at TCT. The webinar will take place at 10 am EST; register here.

Will you attend any of these events and webinars, or have news to share about future ones? Let us know! Discuss this and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the comments below.

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Relativity Secures a New Launch Site in California for 3D-Printed Rockets

A new launch site facility at Vandenberg Air Force Base in Southern California will be Relativity Space‘s latest adoption to its growing portfolio of infrastructure partnerships. With this new addition, the 3D-printed rocket manufacturer’s launch capabilities will now span both coasts of the United States, as the company already has a lease for a launch site in Cape Canaveral, Florida. Ahead of next year’s inaugural Terran 1 rocket launch, these expanded capabilities, along with the company’s autonomous production via metal 3D printing, help drive Relativity’s momentum and customer base at a time when the space industry is booming and the number of rocket launches increases exponentially. 

To build up its launching capabilities, Relativity signed a Right of Entry Agreement with the 30th Space Wing of the United States Air Force to begin the assessment of the viability of launch operations at the prospective site. The location chosen for Relativity’s new launch complex is the current site of Building 330 (B-330) and the adjacent land, a storage facility located just south of SLC-6, the current west coast launch site for United Launch Alliance’s Delta IV Heavy rocket. Moreover, Relativity’s senior leadership team, drawn from both longtime aerospace companies and industry pioneers, has executed dozens of successful launches at Vandenberg.

“We’re honored to begin this partnership with the 30th Space Wing and join the exclusive group of private space companies able to conduct launches at Vandenberg,” said Tim Ellis, CEO of Relativity. “The West Coast launch facilities allow Relativity to provide affordable access to polar and sun sync orbits that are critical for both government and commercial customers. The geographic southerly position of B-330 at Vandenberg offers schedule certainty and increased launch frequency that will be advantageous to our Terran 1 customers.”

Home to the 30th Space Wing, which manages the Department of Defense’s space and missile testing as well as satellite launches into polar and Sun Synchronous orbits (SSO) from the West Coast, the Vandenberg launch site would support Terran 1 as well as future Relativity Space capabilities, offering Relativity’s customers a complete range of orbital inclinations adding to LEO, MEO, GEO, and low inclination orbits possible at Cape Canaveral’s Launch Complex 16.

“The 30th Space Wing takes great pride in supporting the next generation of leaders in space. We are impressed by Relativity’s innovative approach to reinventing aerospace manufacturing via 3D metal printing and robotics paired with an executive team of seasoned aerospace leaders. We look forward to working with Relativity as its West Coast launch partner for many years to come,” stated Colonel Anthony J. Mastalir, 30th Space Wing commander at Vandenberg Air Force Base.

Relativity’s Los Angeles facility (Credit: Relativity Space)

Disrupting 60 years of aerospace, the California-based startup is pushing the limits of additive manufacturing as it attempts to 3D print entire orbital-class rockets. Originally based in Los Angeles, the autonomous rocket factory and launch services leader for satellite constellations recently moved its work to a 120,000 square foot site in Long Beach, California, that will house both the company’s business operations and an unprecedented manufacturing facility to create the first aerospace platform that will integrate intelligent robotics, software, and 3D autonomous manufacturing technology to build the world’s first entirely 3D printed rocket, Terran 1. 

Up until now we only heard of four customers onboard the Terran 1 manifest, which are Telesat, mu Space, Spaceflight, and Momentus Space. However, Relativity also revealed on Wednesday, via a Twitter post, its fifth launch contract with satellite operator Iridium Communications. According to the company, as many as six Iridium NEXT communication satellites would launch no earlier than 2023 from the new launch site to be constructed at Vandenberg.

Iridium’s CEO, Matt Desch, explained that “Relativity’s Terran 1 fits our launch needs to LEO well from both a price, responsiveness and capability perspective.”

Focused on expanding the possibilities for the human experience by building a future in space faster, and starting with rockets, Relativity has been working to pioneer technology that allows them to reduce the part count 100 times by printing across Terran 1’s structure and engines, also significantly reducing touchpoints and lead times, greatly simplifying the supply chain and increasing overall system reliability.

Launch Complex 16 at Cape Canaveral, Florida (Credit: Relativity Space)

Throughout the last five years, the company has conducted over 300 test firings of its Aeon rocket engines as part of an engine test program conducted at test complex E4 and E2 at NASA’s Stennis Space Center in Mississippi. Powered by liquid methane and liquid oxygen, nine Aeon 1 engines will power Relativity’s first Terran 1 vehicles to LEO. According to NASA Spaceflight, the propellant choice for Aeon 1 is consistent with Relativity’s stated goal of enabling an interplanetary future for humanity, especially since methane and oxygen are expected to be the easiest rocket propellants to produce on Mars. As well as highly automated 3D printing manufacturing methods that can become extremely relevant to future interplanetary space travel.

Relativity is quickly advancing towards launching the first entirely-3D printed rocket to space as it continues to engage in public-private partnerships. In fact, this last agreement represents yet another milestone that the company secured with federal, state, and local governments and agencies across the United States Government. As the first autonomous rocket factory and next-generation space company, Relativity aims to produce an innovatively designed and manufactured rocket, just in time for the upcoming new space race, where startups have the opportunity to be part of an entirely different, unknown, and competitive big new frontier for the private space industry.

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3D Printing Webinar and Virtual Event Roundup, June 23, 2020

We’ve got three upcoming webinars to tell you about in this week’s roundup, with two taking place at the same time on June 24th. The first one is focused on metal 3D printing, while the second is about how to use the technology to unlock massive value, specifically in the food and beverage manufacturing sector. Finally, Stratasys is holding the first of two webinars about aerospace 3D printing on June 25th.

BIG 3D Metal Printing Webinar

This Wednesday, June 24th, at 11 am EDT, EOS North America and Additive Manufacturing Customized Machines (AMCM) are hosting the free “BIG 3D Metal Printing” webinar, focusing on how technology advancements in additive manufacturing are driving applications in commercial space hardware. In this one-hour course, attendees will learn why metal 3D printing is more accessible, what DMLS technology is, what materials can be leveraged, and how customized 3D printing is continuing to advance. The speakers – Martin Bullemer, Managing Director of AMCM; Dr. Ankit Saharan, Manager of Research and Applications Development at EOS North America; and Graham Warwick, Aviation Week’s Executive Editor for Technology – will discuss what metal 3D printing is truly capable of creating.

“The challenges of fast development and innovation have lessened because of industrial metal 3D printing (additive manufacturing, or AM). Whether propulsion, structural, or integrated componentry, AM is accelerating the latest space race.

“Now, AM is moving quickly to meet even greater requirements—such as fully 3D printed combustion chambers with high-performance features, lighter weight structural components, or even fully 3D printed satellites. The latest advancement? Fully printed 3D components up to one (1) meter tall.”

Register for the free webinar here.

3D Printing for Food and Beverage Manufacturers

Ultimaker is also holding a free webinar at 11 am EDT this Wednesday, titled “3D printing for food and beverage manufacturers.” If you don’t want to miss either one, you also have the option of attending the first broadcast session of this webinar at 5 am EDT. Even if you’re not in the food and beverage industry, this 50-minute webinar could still be useful, as the company “will be revealing some of the best ideas and strategies that we use to help our biggest customers unlock massive value with 3D printing.”

Ultimaker’s Director of Community Development, Matt Griffin, and Application Engineer, Jeremy Evers, will discuss which AM applications in this industry are currently working, and how to use the technology to achieve excellent results, such as reduced costs, increased line uptime, and optimized efficiency. During the webinar, they will give examples of industry-proven applications that have saved Ultimaker customers a lot of money, provide two sample criteria that the company’s application engineers use to determine which applications can achieve the largest ROI, discuss the future of 3D printing in the food and beverage industry in a post-coronavirus market, and more. Additionally, attendees will have the chance to participate in a live Q&A afterwards. Register here.

Stratasys Aerospace Webinar Series

This Thursday, June 25th, at 10 am EDT, Stratasys will be hosting the first in its new aerospace webinar series, titled “Challenges Of Manufacturing Aircraft Production Parts.” Niccolò Giannelli, Aerospace Application and Account Manager EMEA for Stratasys, will speak during this hour-long webinar about how certifying 3D printed aircraft parts for installation is easier with the company’s Aircraft Interiors Solution (AIS).

Some of the topics to be discussed in this first webinar include the value of both Stratasys’ AM solution and additive manufacturing for aircraft production parts, what comes in the Stratasys AIS package, and the improved performance of airline companies after they’ve implemented the Stratasys Aircraft Interiors Solution. Register here. The next webinar in this series will be held on June 30th.

Will you attend any of these events and webinars, or have news to share about future ones? Let us know! Discuss this and other 3D printing topics at 3DPrintBoard.com or share your thoughts in the comments below.

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Made In Space Acquired by New Space Company Redwire

In an era of endless mega-mergers and acquisitions, perhaps nearly every startup’s dream is to one day become big enough to be bought out. That dream has now been fulfilled by Made In Space (MIS), the company to first install a 3D printer in the International Space Station (ISS). MIS has announced that it was purchased by a firm called Redwire.

Made In Space’s Additive Manufacturing Facility, the first commercial 3D printer in space. Image courtesy of Made In Space.

MIS is already well-known in the additive sector for its work in 3D printing in space. In addition to the aforementioned ISS machine, the company subsequently sent up the first commercial system in space. This allowed customers to print objects on the ISS. Other projects explored by MIS include the Archinaut, a system meant for the additive construction of large-scale objects, such as satellites, in space, as well as in-space fiber optics pulling, material recycling, and metal 3D printing.

While, in many cases, corporate buyouts are performed by much more established businesses to grow their portfolios, MIS has announced that it was purchased by Redwire, a seemingly unknown new space company. Part of the reason for Redwire’s lack of name recognition is the fact that it was only formed in June 2020, the result of strategy by private equity firm AE Industrial Partners. AEI acquired two other space firms, Adcole Space and Deep Space Systems (DSS), earlier in 2020 to form Redwire. The company’s goal is to be a leader in “mission critical space solutions and high reliability components for the next generation space economy.”

In the new space industry, there is plenty of opportunity to take advantage of media and investment hype due to the fact that much of the sectors goals are on a very protracted timeline. Mining on earth has already proven to be ripe for fraud, as discovery and extracting valuable metals can take years to achieve and may never be realized, allowing the purported mining operations to cover up financial malfeasance. Mining asteroids in space is that much more abstract.

For this reason, it would pay to be skeptical of nearly any new space company. However, whereas Redwire may have come out of the blue, AEI and the companies purchased have much more established histories. AEI was founded in 1998 to expand middle market aerospace companies using its team of over 30 investment staff and resulting in the closure of 46 acquisitions.

The team is made up of numerous aerospace veterans, with Managing Partner David Rowe having served at GE Aerospace and GE Capital before becoming executive vice president at Gulfstream Financial Services Corp. and then building AEI. Other members worked at such companies as UBS, Boeing, GE and Hawker Beechcraft, with some serving as U.S. federal officials, including former acting Department of Homeland Security secretary Kevin McAleenan.

Commercial Lunar Payload Services Small Lunar Lander from Deep Space Systems. Image courtesy of Deep Space Systems.

Both DSS and Adcole Space are fixtures in the space industry, with DSS involved in the development and management of space systems, including parts and spacecraft. Since its founding in 2001, DSS has created complete spacecraft, data recovery systems, fully qualified payloads and has been involved in projects related to the Space Shuttle, ISS, Orion, Dream Chaser and more. Adcole Space was founded in 1957, when it began working on satellite technology that has since been used in hundreds of low-earth orbit, geosynchronous and interplanetary spacecraft, including missions to Mercury, Mars, Jupiter, Saturn and Pluto.

The purchase of MIS is meant to expand Redwire’s portfolio from space sensors and payloads, flight hardware and space craft to include MIS’s in-space manufacturing technology.

Of the acquisition, Redwire CEO Peter Cannito said, “To truly realize the full potential for space exploration, innovation must change the economics. Made In Space has been driving these innovations and is now positioned to revolutionize the industry.”

Cannito, it is worth noting, worked as an operating partner at AEI after serving as CEO of Polaris Alpha, a developer of technology for the Department of Defense and the intelligence community.

In other words, while Redwire may be new as a business entity, its team is not, and MIS is joining what may be an altogether formidable group of space experts. It will be taking along with it its sister company, Made In Space Europe, which develops space-capable robotic systems. In addition to its headquarters in Jacksonville, Florida, MIS has offices in California, Alabama and Ohio. Andrew Rush, president and chief executive officer of MIS, said that the purchase by Redwire would allow the company to grow and advance its technology.

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