Though the promise of additive manufacturing has led more companies to experiment with the technology, three key industry challenges must be solved before we see widespread mainstream adoption of additive manufacturing approaches: certification of additive parts, the design toolchain, and training for engineers.
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The 3 Breakthroughs Additive Manufacturing Needs Most When the concept of additive manufacturing (AM) first entered the public sphere nearly 40 years ago, its applications were mainly focused on fabricating small, complex items with plastic polymers. In the decades since, our understanding of additive manufacturing’s potential benefits has exploded while costs have dropped, leading to breakthroughs like fabricated organs and prosthetics and the proliferation of 3D printers in K-12 classrooms around the world. Today, additive manufacturing has the potential to unlock new sophisticated design and production capabilities for industrial companies, allowing manufacturers to produce customized goods and deliver parts faster. However, the powerful machines needed to additively manufacture mission-critical parts are much more complex than a classroom model, especially on an industrial scale. According to a recent survey, 61% of manufacturing companies now use additive approaches to produce at least 10% of their functional or end-use products (up from 36% in 2017). Seventy-four percent currently use plastic polymers, but there is a large demand for better metal, ceramic, and glass materials. A2Z Manufacturing Rocky Mountain •
22 May / June
2019
Challenge #1: Certification In order for an additivelymanufactured (AM) safety-critical part to move from conceptual design into commercial or military aerospace use, regulators must first approve it. While conventionally manufactured par ts have the advantage of decades of knowledge in manufacturing processes, various types of potential defects and field experience, the certification process for AM parts needs to be more rigorous because it is still an emerging technology. In AM, the material properties are strongly dependent on local thermal history to the extent that the material microstructure (grain size and shape) could be different in the XY plane and in build direction (Z). Moreover, material properties could vary from one location in a part to another based on the design features. In many ways, the burden is on the manufactur ing companies to demonstrate to certification authorities like the FAA, European Union Aviation Safety Agency (EASA), and Department of Defense that additively manufactured parts meet the design intent. We must also demonstrate a thorough understanding of the key process variables and their impact on material properties and design limits. The best way for the industry to tackle this challenge is to develop