Strut-Truss Design, 3D Printing Reduce Mass of Satellite…

Strut-Truss Design, 3D Printing Reduce Mass of Satellite…

Sep 26, 2017

“Strut-Truss Design, 3D Printing Reduce Mass of Satellite Structural Components” Featured in Design-2-Part Magazine PALO ALTO, Calif.—Space Systems Loral (SSL), a provider of satellites and spacecraft systems, recently announced that it has successfully introduced next-generation design and manufacturing techniques for structural components into its SSL 1300 geostationary satellite platform. Its first antenna tower that was designed using these techniques, which include additive manufacturing (3D printing), was launched last December on the JCSAT-15 satellite, the company said in a press release. “SSL is an innovative company that continues to evolve its highly reliable satellite platform with advanced technologies,” said Dr. Matteo Genna, chief technology officer and vice president of product strategy and development at SSL, in a company release. “Our advanced antenna tower structures enable us to build high performance satellites that would not be possible without tools such as 3D printing.” The highly optimized strut-truss antenna tower used on JCSAT-110A consisted of 37 printed titanium nodes and more than 80 graphite struts. The strut-truss design methodology is now standard for SSL spacecraft, with 13 additional structures in various stages of design and manufacturing, and has resulted in SSL’s using hundreds of 3D printed titanium structural components per year, according to the company. “We would like to thank our customer, SKY Perfect JSAT, for partnering with us on this important satellite manufacturing advance,” said Paul Estey, executive vice president, engineering and operations at SSL, in the release. “This breakthrough in satellite design is an example of SSL’s holistic approach to new technologies and its teamwork with satellite operators that need to maximize their satellites’ capability.” For SSL (www.sslmda.com), optimizing at the system level with additive manufacturing is reported to have enabled an average of 50 percent reductions in mass and schedule for large and complex structures. The savings over conventionally manufactured structural assemblies are much greater than what is possible with the optimization of an individual part. Since the launch of JCSAT-110A, SSL has completed assembly and testing on several other strut-truss structures and continues to expand its use of additive manufacturing and other next-generation design and manufacturing techniques, the company...

A way to make 3D printed parts stronger

A way to make 3D printed parts stronger

Sep 21, 2017

By Bill Bregar, Plastics News Brandon Sweeney, a doctoral student at Texas A&M University’s Department of Chemical Engineering, has developed a way to make 3D printed parts 275 times stronger. Sweeney, working with his adviser Micah Green, associate professor of chemical engineering, applied traditional welding concepts and a carbon nanotube composite filament to bond the submillimeter layers in a 3D printing part using focused microwaves. Sweeney began working with materials for 3D printing while he was employed at the Army Research Laboratory at the Aberdeen Proving Grounds in Maryland. “I was able to see the amazing potential of the technology, such as the way it sped up our manufacturing times and enabled our CAD designs to come to life in a matter of hours,” Sweeney said. “Unfortunately, we always knew those were not really strong enough to survive in a real-world application.” When he started his doctorate studies, Sweeney was working with Green in the chemical engineering department. Green had been collaborating with Mohammad Saed, assistant professor in the electrical and computer engineering department at Texas Tech, on a project to detect carbon nanotubes using microwaves. The three men came up with an idea to use carbon nanotubes in 3D printed parts, then using microwave energy to weld the layers of parts together. “The basic idea is that a 3D part cannot simply be stuck in an oven to weld it together, because it is plastic and will melt,” Sweeney said. “We realized that we needed to borrow from the concepts that are traditionally used for welding parts together where you’d use a point source of heat, like a torch or TIP welder, to join the interface of the parts together. You’re not melting the entire part, just putting the heat where you need it.” The team puts a 3D printed filament and apply a thin layer of a carbon nanotube composite on the outside. “When you print the parts out, that thin layer gets embedded at the interface of all the plastic strands,” Sweeney said. “Then we stick it in a microwave, we use a big more sophisticated microwave oven in this research, and monitor the temperature with an infrared camera.” The patent-pending...

Your Shoes Will Be Printed Shortly

Your Shoes Will Be Printed Shortly

May 16, 2017

By Christopher Mims, Wall Street Journal Innovative techniques in 3-D printing mean some previously impossible design will start showing up in consumer products This may be the year you get 3-D-printed shoes. By the end of 2017, the transformation of manufacturing will hit a milestone: mass-produced printed parts. Until now, that concept was an oxymoron, since 3-D printing has been used mainly for prototyping and customized parts. But the radical innovation of 3-D printing techniques means we are finally going to see some previously impossible designs creep into our consumer goods. In the long term, it also means new products that previously would have been impractical to produce, and a geographical shift of some manufacturing closer to customers. I have two very different examples of this milestone, one plastic, the other steel. There’s a running shoe from Adidas AG, with a 3-D-printed latticed sole that looks almost organic, like the exposed roots of a plant. Then there’s a steel hinge, indistinguishable from any other metal part except for incredibly fine striations in its surface, as if it had been deposited like sandstone rather than forged. In a feat impossible with conventional manufacturing, all three moving pieces of the hinge were crafted together. 3-D printing is more than two decades old, but to date the process has been limited to making novelties, prototypes, bits of machines for factories, or expensive specialized parts, like fittings for prosthetic limbs or fuel nozzles in jet engines. After years of searching for a 3-D printing tech that is up to the challenge of sneakers, Adidas came upon a startup called Carbon Inc., which has raised $222 million to date. Instead of the plodding process of depositing plastic one layer at a time from a nozzle, Carbon’s “digital light synthesis” printers transform a liquid plastic into a solid using UV light and oxygen. This yields products comparable in quality to molded plastics at a competitive speed and cost, at least when making tens of thousands of a given object. Why Now? Because traditional manufacturing requires molds, casts and machining, it has high upfront costs. It’s great if you want to make a million of something, but not so great if you...

3D printing could usher in a revolution, but small…

3D printing could usher in a revolution, but small…

Mar 30, 2017

“3D printing could usher in a revolution, but small, local businesses unlikely to benefit” By Kevin Smith, San Gabriel Valley Tribune Large manufacturers benefitting from advances in 3D printing and other technology are saving time and money, but the speed of change will likely leave small and mid-sized companies behind. Gregg Profozich, director of advanced manufacturing technologies for California Manufacturing Technology Consulting (CMTC) in Torrance, said nearly 99 percent of U.S. manufacturing businesses are considered small, with many employing 20 or fewer workers. And integrating the latest technology — regardless of its efficiency — is often not a priority for these businesses. For many, it’s not even possible. “The problem is that most small manufacturers are so busy working in the business that they can’t work on the business,” he said. “When Joe doesn’t show up they have to go run the press mill, or the injection molding machine or they have to do the billing. They are in the business but they are not stepping back. They don’t have a department for stepping back and thinking about the future, and that’s where we try to come in. That’s what my role is about, to think about new technologies that we might be able to use to help them adopt.” Profozich was a featured speaker at Tuesday’s “Exploring the Next Generation of the Technology Revolution” forum at Caltech’s Athenaeum. The event was sponsored by Technolink Association, a coalition of leaders in aerospace, academia, innovation and other fields who are seeking to develop a virtual high-tech corridor in Southern California. Profozich displayed a pair of slides that clearly illustrate how manufacturing processes have become more efficient. The first showed a circular metal piece that had been machined out of a large metal block by a CNC (computer numerical control) cutting tool. The piece was surrounded by piles of metal shavings that had been carved away to create the part. “It’s like the old sculptor who starts with a block and keeps chiseling away until you end up with the art you want,” he said. “That’s the mentality we had the past. But now we have technologies that allow this.” At that point he displayed another slide that showed...

HP reveals next move in making 3D printing competitive…

HP reveals next move in making 3D printing competitive…

Mar 27, 2017

“HP reveals next move in making 3D printing competitive with injection molding” By Norbert Sparrow, Plastics Today HP (Palo Alto, CA) has a storied past, but it may have an even more glorious future if it is able to deliver on its vision of industrial-scale 3D printing that can rival injection molding. Its opening salvo in achieving this long-term ambition came just about one year ago, when it unveiled the HP Jet Fusion 3D Printing Solution, which prints quality parts up to 10 times faster and at half the cost of current 3D printers, according to HP. The newest milestone came last week, when it launched its 3D Open Materials and Application Lab at its sprawling facility in Corvallis, OR. HP invited several journalists, myself included, and analysts to tour the lab and to lay out its strategy for embedding 3D printing within the $12 trillion manufacturing sector. The Corvallis facility, a stone’s throw from Oregon State University’s Reser Stadium, was the birthplace of thermal inkjet technology some 30 years ago, and remains a hotbed of innovation, where material scientists and engineers design, test and build printheads, silicon wafers and thermal inkjet printer heads. Right now, all eyes are on the capabilities of its additive manufacturing system and the development of compatible materials. Multi Jet Fusion is the culmination of decades of research, Timothy Weber, PhD, Vice President and General Manager of 3D Materials and Advanced Applications, told journalists during the site visit. “The total market for 3D printing is around $5 to $6 billion,” said Weber. “The market wasn’t big enough to interest a $50+ billion company like HP, and we didn’t have a technological differentiator,” he added to explain why the company waited as long as it did before dipping its toe in the additive manufacturing pond. That changed with the development of Multi Jet Fusion technology, which has the potential to compete with conventional plastics processing techniques, and the ability to engineer materials at the voxel level. The mighty voxel HP describes the voxel as a volumetric pixel. With Multi Jet Fusion, HP can manipulate materials at the voxel level by dosing liquid functional agents in the powder bed as the parts are...