Boeing 777x Takes First Flight with over 600 3D-Printed Parts

Sunday saw the maiden flight of the Boeing 777X, marking an important date in the history of 3D printing for the twin GE9X engines driving the aircraft. Each GE9X features roughly 300 3D-printed parts made by GE Additive’s Technology Center in Ohio and the team at Avio Aero in Italy. The event was so momentous that Boeing tracked the flight live that day.

An upgrade to the Boeing 777, launched in 1994, the 777X is instantly recognizable for its carbon fiber, folding wing tips, which allow the craft to park in the same bays as other planes. The 777X is being billed as the largest and most fuel-efficient twin-engine jet on the planet, due to a 10 percent decrease in fuel use and emissions. One might wonder the worth of celebrating the flight of a new aircraft, given the massive carbon footprint of the aerospace industry, but, unless flying becomes more heavily regulated, any improvement in emissions is worth noting.

This reduction in emissions was achieved in part by a new aerodynamic design and the GE9X engines. As wide as the body of a Boeing 737, the GE9X is the world’s largest engine on any commercial plane. This size was achieved through the use of advanced fiber composites that made it possible to drop the number of blades in the system from 22, as seen in the GE90, to just 16. In addition, the GE9X features the now famous 3D-printed fuel nozzle, which reduced part count from 20 to just one.

A GEnx engine on a test stand in Peebles, Ohio. Image courtesy of GE Aviation.

Other features, such as the use of light and heat-resistant ceramic composites for the engine shroud, not only result in increased weight and fuel savings, but also render the GE9X the most powerful engine on any commercial aircraft. It delivers up to 100,000 pounds of thrust.

After the GE9X underwent a test flight in March 2018, they have been outfitted onto a 777x, which was scheduled for its first take-off on Saturday, January 25, but delayed due to weather. The following day, the aircraft took off from and landed at Boeing Field outside of Seattle.

The Boeing 777X is competing with the Airbus A350 XWB, in terms of size, performance and number of 3D-printed parts. The A350 already features over 1,000 3D-printed parts, including cabin parts made using Stratasys technology, titanium pylon brackets, and a cabin spacer 3D printed by Materialise. What it doesn’t have is a recent history of catastrophic engine failures associated with the 737 MAX engines.

This latest PR event may help some tech enthusiasts forget the recent tragedies associated with the 737 MAX, but the company will have to do more to gain the reassurance of the FAA, its customers and the public. Naturally, the FAA has said that it will ensure a rigorous review of the aircraft, after its neglect over the 737 Max, and Boeing has said that it will also perform thorough testing to achieve FAA certification. Emirates, the aircraft’s launch customer, has said that it wants the plane to be put through “hell on Earth” during testing.

The 777X is expected to enter service in 2021, which is a year later  than originally scheduled. The A350, on the other hand, has already begun flying.

The post Boeing 777x Takes First Flight with over 600 3D-Printed Parts appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

ABB Robotics Adds 3D Printing to RobotStudio Software

Industrial robotic arms are no strangers to 3D printing. Their great dexterity and flexibility have made them increasingly powerful platforms for a variety of 3D printing processes. Swiss tech giant ABB has caught on and has added 3D printing capabilities to the latest edition of its RobotStudio simulation and offline programming software.

Numerous customers have already begun using ABB robots for 3D printing purposes. One of the most notable may be MX3D, which outfitted its industrial robotic arm with a wire arc welding system to 3D print large-scale metal objects, including a bridge in Amsterdam. Viridis3D also uses a standard ABB robot to perform a unique take on 3D printing sand for metal casting.  You’ll also come across countless researchers taking advantage of these robots for new 3D printing applications.

Clearly catching on to the growing adoption of its tools in the additive manufacturing space, ABB is hoping to make it easier for users to do so. Part of the PowerPac portfolio, RobotStudio removes the need for manual programming for 3D printing. According to the company, the software’s new 3D printing feature will allow users to program ABB robots for AM in just 30 minutes. This includes such 3D printing processes as welding, concrete or printing with polymer granules.

ABB highlights the fact that any 3D printing slicer software can be converted into ABB’s simulation environment and robot code. The company suggests that this process is faster than plotting a toolpath for a traditional printing system.

Established over 130 years ago, ABB has roughly 147,000 employees spanning more than 100 countries. Despite its size and legacy, it is not the only manufacturer competing in the 3D printing space. Other companies who have seen their robotics featured in AM processes include Yaskawa, Comau, KUKA, Universal Robots, FANUC and Schunk.

Of these, FANUC is the only one to sell a system specifically for 3D printing, a collaborative wire arc welding robot. Comau and KUKA are comparable to ABB in terms of the way that their robots have been used for AM, while Universal Robots sells less expensive, less industrial machines that have been used by the likes of Voodoo Manufacturing.

The drive for the use of these machines is not just the fact that many of them can be used to fabricate large-scale structures, but also that they would be more easily integrated into an already existing manufacturing environment, where industrial robots are already the norm. Therefore, as AM becomes more widely adopted in a factory setting, robotics companies have a greater incentive to find ways to work with AM technology.

In other words, many makers of industrial robotic arms have begun to catch on to the growing adoption of their products for 3D printing. As AM grows, this number will surely increase, further motivating companies like ABB to accommodate their new customer base. It’ll be interesting to see what the next move by a large robotics company will look like.

The post ABB Robotics Adds 3D Printing to RobotStudio Software appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

El Paso scientists to deliver 3D bioprinted miniature hearts to the ISS

Biomedical researchers from Texas Tech University Health Sciences Center El Paso (TTUHSC El Paso) and The University of Texas at El Paso (UTEP) are collaborating to develop artificial mini-hearts using 3D bioprinting technology for space.  These heart-tissue structures will be sent to the International Space Station (ISS) to gain insight into how microgravity affects the […]

Urwahn and Schmolke unveil racing bike with 3D printed steel frame

German bicycle manufacturer Urwahn Bikes has partnered with lightweight bike component specialist Schmolke Carbon to develop a racing bike featuring a 3D printed frame.  A limited-edition release, the bicycle in question combines Urwahn Bikes’ 3D printed steel frame with carbon fibre bike parts developed at Schmolke. “Together we have used the potential of 3D printing […]

Researchers develop Hybrid Living Materials using inkjet 3D printing

Researchers from the MIT Media Lab, Harvard University’s Wyss Institute, and the Dana-Farber Cancer Institute have developed a method to 3D print objects that can control organisms.  Dubbed as the Hybrid Living Material (HLM) fabrication platform, the team used a multi-material inkjet-based 3D printer and customized recipes for the combinations of resins and chemical signals. […]

The Maker Movement Unmade? Part 5: The Community Responds

With this series, we’ve explored the changes that have occurred within the maker movement with the thesis that it seems to have fallen apart. Based on community feedback and some actual numbers, that thesis is likely incorrect. More accurately, the maker movement seems to have become integrated into mainstream society, particularly in educational spaces. And it has perhaps been the neglect from the media, in part, that has allowed the movement to fade from view.

Limor Fried, founder of open hardware supplier Adafruit, was quick to point out to 3DPrint.com that the “maker movement” is not defined by any one publication or company in the space and that “there are more publications for makers now (hackspace, etc.) and more electronics, more events, and even more things to do. [T]here are more open-source software and hardware projects than ever.”

The Open Source Hardware Association (OSHWA) keeps running tabs of the projects with OSHWA certification, currently numbering just under 400. The list continues to grow, with new additions as recently as January 13, 2020. At the beginning of the year, designer Mark Mellors uploaded a number of interesting 3D printable medical devices, such as an umbilical cord clamp and otoscope specula.

Since it was founded by Limor Fried in October 2005, Adafruit itself has been a demonstration of the overall growth of DIY/hacking culture. In the open source spirit, the company has regularly updated its community about the number of products it has shipped. As of December 2019, Adafruit had over 2,211,443 orders with revenue of over $40 million. Crucially, the company has had no loans, nor any venture capital.

A chart made using Adafruit’s public information about year-on-year growth.

That doesn’t mean that the maker movement hasn’t changed. In addition to the metamorphoses of some companies, the preferences of the community itself have changed. For instance, the Adafruit team says that “in the past there was a lot of Arduino, but the market has moved to the most popular programming language for a lot of hardware (python) and for the physical format, feather, there are hundreds of boards and wings.”

The trick, according to the people closest to the open hardware community, is not to necessarily look at the original and bigger names in the maker movement. In addition to some of the companies we covered in a previous installment, there are names like TechShop that, at one point, became associated with the maker movement. While TechShop went out of business (using a for-profit model, it should be noted) and its CEO Mark Hatch failed to launch a maker-inspired bitcoin, other companies have been quite successful.

While the RepRap forums aren’t quite as active as they used to be, both the Adafruit team and Adrian Bowyer, founder of the RepRap Project, pointed out that Prusa Research now sells more 3D printers than any other company. The company was founded by RepRap legend Josef Prusa, whose Prusa RepRap design was replicated and, in some cases, commercialized numerous times by the open hardware 3D printing community.

Based on some always helpful research from Adafruit, Prusa Research had sold 150,000 3D printers. These aren’t just any desktop machines, but RepRaps—that is open source printers with many parts 3D printed on other open source 3D printers or self-replicating machines. The company earned roughly €33M in revenue in 2017 and, according to Deloitte, was the fastest growing tech company in Central Europe in 2018, growing at a rate of 17,118 percent over the previous four years.

Another legendary RepRapper, Richard “RichRap” Horne assured us that “[t]he maker culture is very much alive, always transforming and evolving.” Horne suggested that a community, whether in the form of a Makerfaire or a virtual space, is one that many DIY enthusiasts would likely want to pay for:

Whilst people happily pay for materials, tools and software the idea of paying to access an online community is not quite as compelling because so many highly focused knowledge sharing repositories already exist, they also need to be both niche and be able to accommodate and share ideas from anywhere (feeling independent), being behind a paywall or as a subscription service is unlikely to work in my view.

He also said that “[t]he RepRap movement is also going strong; it’s also slowly transitioning to another level of user and technology adoption. We are seeing constant developments of new ideas that are leading to ever more useful machines and commercial businesses.” Horne pointed out:

[T]he RepRap project launched thousands of companies to ‘feed’ the open-source 3D printing revolution, some of these like Prusa and E3D have taken that to the next level of both business (product sales) and circular developments of highly user focused products.

I’m quite interested to see what open-source hardware companies do to expand and also cultivate their communities of dedicated users and contributors. These companies may have the power (and funds) to help sustain and grow all sorts of niche developments and therefore build on that symbiotic relationship.

For his part, Horne is working on tool-changing technology and is still developing next generation paste extruders for food- and non-food-based 3D printing. Adrian Bowyer is working on a 3D printer that uses an electric current to cure a photopolymer resin that would rotate around the vat like a CT scan.

Adrian Bowyer’s schematic for an electric current 3D printer. This project definitely requires its own article. Image courtesy of Adrian Bowyer.

Another RepRapper, Nicholas Seward, currently works as a teacher, but still builds 3D printers in his spare time. He is involved in some exciting projects, including: a print bed that can actively heat and cool along with an automatic part ejection system, his RepRap WHEELIOS and HELIOS designs, and a prototype for backpack-sized printer that uses a SCARA arm to roll open a door so that it can print something as large as a human. He’s also starting to build RepRaps with six-degrees of freedom, either a Sextupteron or Stewie Simpson, but hasn’t decided which yet. If you look into any of these projects, you’ll see that they have some of the most interesting architectures imaginable.

Seward believes that the maker movement is mirroring the hype cycle generally associated with new technologies. He suggests that it may be fracturing back into sub-disciplines as the unified culture symbolized by some brands was too big to maintain. As for RepRap, Seward sees 3D printer development moving back into the private space, arguing that the concepts of patents and intellectual property are hindering what could be a much more rapid evolution of these technologies:

Open source is a big deal to me. I think patents are in some ways horrible for humanity… The only reason the RepRap project could do what it did was because the FFF patents expired right when it started…there is more and more pressure for patents and secrecy.  I have signed a…ton of NDAs (for consulting work) for companies that want to be open but are dealing with traditional funding models and expectations. I can’t fault them and I freely work for them (to a degree).  Even if I help them get to an idea that they patent, it might inspire others and eventually everyone can use the patent. You have to work within the system or you go out of business.

In the next installment in our series, we will continue to relay the feedback of prominent makers, including Joshua Pearce of Michigan Technological University and former Autodesk CEO Carl Bass.

The post The Maker Movement Unmade? Part 5: The Community Responds appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

8 Reasons Why 3D Modeling is in Demand in Architecture

3D modeling is increasingly used in various fields of human life and activity. For a long time, that technique has gone beyond the use of purely in the entertainment industry, although there it is still actively being introduced and improved. But not only games and animation are the main consumers of 3D models.

Today, more than ever, this technology is in demand in architecture and construction. And we will give you as many as 8 reasons for the popularity of 3D in these areas.

Reason 1: Realism

   Although the main drawings of any architectural structure are carried out in two-dimensional space, it is the 3D layout that allows us to evaluate their accuracy and compliance with the set goals, construction standards and utility. As a tradition, architectural design is the creation of textual and graphic documentation. Using three-dimensional modeling, the design process greatly simplifies and speeds up the creation of functional prototypes – as a result, the architect and the customer receive a functional prototype, the finalization of which takes a minimum of time and has maximum efficiency.

   For many years, architectural companies have been using CAD (Computer-Aided Design) to create projects. But if you need a model with maximum accuracy and detail, it is much easier to order it from a special company that is directly involved in the development of three-dimensional samples, including building a 3D model.

Reason 2: Speed

   When architects worked with paper, the time they needed to perform at least basic drawings and visualizations was very long. Building a 3D model using computer technology takes much less time, while it is almost impossible to make mistakes in the calculations.

   Now you do not need to delay the moment of presentation to the customer of your project – just use the finished model or order its production according to your references.

Reason 3: Detail Quality

    We already touched on this parameter in the first paragraph, but it is worth noting it separately: modern software in the hands of a skilled specialist allows you to achieve maximum compliance of details with customer requirements or the ideas of the designer. As a result, you get a ready-made layout that you can rotate in space to consider the quality of wall decoration, the interior, or even the decor pattern on the walls.

Reason 4: The Ability to Create a Full-Fledged Layout Based on the 3D Model

   Technologies are easily combined, and modern architectural 3D models can be embodied not only on a computer screen but also transferred to a completely tangible form. Get a three-dimensional image of your project and just print it using a 3D printer – the layout is ready! If your customers require you to visualize your idea, this is a great solution.

Reason 5: Possibility of a Good Study of Internal Zoning

   This reason is especially relevant for commercial construction. A full-scale model allows zoning the area with greater efficiency, “filling” the internal space of trading floors and galleries with goods and decor items, as well as “testing” the convenience of layout from the point of view of customers and employees.

Reason 6: Advertising

   If you initially set the task of promoting the projected project, whether it be an apartment building, a skyscraper or a future shopping center, it is the ready-made visualization in three-dimensional space that will help you with this. Use it in commercials, engage in promotional materials or present at architectural exhibitions and negotiations with investors – when a potential buyer sees exactly what he is going to pay his money for, his credit of trust in you will increase significantly.

Reason 7: Revision

    If you are trying to implement a building concept that exists only in the imagination of the customer, all ideas and concepts can easily be embodied in the primary model, the process of finalizing which in terms of functionality and aesthetics will take a minimum amount of time;

Reason 8: Money

   Ordering an architectural 3D model is always profitable because it allows you to save on several things at once:

• The painstaking manual work of a designer or architect, who will need to pay for difficult work.

• On making additions and reworking the order.

• On a separate development of layouts for the customer and advertising: a three-dimensional model can serve both here and there.

Three-dimensional technology rules the world. They show it realistically and in detail. This is especially noticeable in the example of the use of 3D models in architecture.

The post 8 Reasons Why 3D Modeling is in Demand in Architecture appeared first on 3DPrint.com | The Voice of 3D Printing / Additive Manufacturing.

A 3,000 Year Old Egyptian Mummy “Speaks” After His Vocal Chords Are 3D Printed #archeology #3Dprinting

It’s not much, “a bit like a long, exasperated meh without the m,” but how amazing is it that scientists managed to 3D scan and print the vocal chords of a 3,000 year old mummified Egyptian priest and used them to produce a sound?

Howard is also hoping to conduct a second stage of research on Nesyamun’s vocal tract that could result in reproducing the sound of him singing as he would have done in his role as a scribe and priest during the reign of Pharaoh Ramses XI. His voice was an essential part of his ritual duties, which involved speaking, chanting and singing.

According to Howard, the team’s Egyptian scholars said the phonetics and the music of the songs were known, so “in principle we could make him make different sounds and we could start to reproduce bits of what he actually sang.” To do that, Howard said he would use computer software to build up the tongue based on the average for a vocal tract of that size.

Read the rest on the CNN website.

Adafruit Weekly Editorial Round-Up: All the Internet of Things – Episode 6, 3,000 Thanks, NeoPixel Infinity Mirror Coaster, & more!

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ADAFRUIT WEEKLY EDITORIAL ROUND-UP


We’ve got so much happening here at Adafruit that it’s not always easy to keep up! Don’t fret, we’ve got you covered. Each week we’ll be posting a handy round-up of what we’ve been up to, ranging from learn guides to blog articles, videos, and more.


BLOG

All the Internet of Things – Episode 6 – DK IoT Studio

Adafruit and Digi-Key have teamed up to present All the Internet of Things – a six-episode series covering everything you could ever want to know about the Internet of Things.

http://www.digikey.com/alltheiot

We’ve gone over a lot of different aspects of IoT. In our first episode, we looked at Transports, the physical and wireless mechanisms used to transfer data between things. In Protocols, we saw the communication standards which enable devices at each end of a transport to “speak the same language” and understand what is being communicated.

More BLOG:


LEARN

NeoPixel Infinity Mirror Coaster – Build a Portable Infinity Mirror with Bluetooth Control

More LEARN

Browse all that’s new in the Adafruit Learning System here!