The RAPID 2013 Conference & Exposition Directory - Society of ...

ConferenCe Details
Tuesday, June 11
Applications for Transportation
including Aerospace and Aircraft
10 am–Noon
The session will combine applications using additive
manufacturing for parts and models used in motor vehicles,
commercial and military aircraft, and aerospace.
10–10:25 am
Design Study on an Additively Manufactured
Compressor Casing Containing Auxetic Structures
David Rockel, Dipl.-Ing., Research Associate,
Institute for Flight Propulsion - TU Muenchen
This session will present a new potential application of additive
manufacturing technologies in future aero engine design,
and focus on the practical implementation of the new design
freedom using the example of a compressor casing. The results
show a clear improvement of the tip clearance behavior of the
casing. Design elements are developed in order to adapt the
casing expansion to the rotor throughout an entire load cycle of
an aero engine.
11–11:25 am
New Machine X Line 1000R & Case Studies
of Metal Additive Manufactured Parts Implemented
in Aerospace Industry
Andreas Tulaj, Dipl.-Ing., Regional Sales Manager, Concept Laser
GmbH
C. Malcolm Ward-Close, Professor, Imperial College London
Additive manufacturing with metals is becoming increasingly
important in many areas of industry. Time and cost reductions
in production are making this generative technology more
and more attractive even for medium-sized quantities and
larger components.
With this in mind, Concept Laser, together with the Fraunhofer
Institute for Laser Technology (ILT) and the automotive partner
from industry Daimler AG developed a new high-performance
machine named X line 1000R whose build chamber size
surpasses anything that was previously known. By using
a 1 kW fibre laser system, the layer thicknesses and track
widths can be increased by several factors, which means that
productivity can be increased more than ten-fold compared with
conventional systems.
10:30–10:55 am
Development of a Lightweight Hydraulic Valve
Manifold by Selective Laser Melting Technology
Gerhard Hummel, Dipl.-Ing., MSC, Hydraulics System Engineer/
Designated Certification Specialist, Airbus Operations GmbH
Frank Schubert, Dipl.-Ing., Scientific Staff Member,
Chemnitz University of Technology
Alexander Altmann, Dipl.-Ing. (FH), R&T Project Manager,
Liebherr-Aerospace Lindenberg GmbH
This session will show the development process of a SLM valve
manifold based on Airbus A380 equipment. In consideration
of functional hydraulic schematics, installation and interface
requirements, the rearrangement of sub-components and
connector system was performed. Additionally SLM design
directives, including strategies for supporting structure and postprocessing
reduction, were developed and applied.
11:30–11:55 am
Selective Laser Sintering (SLS) of Next Gen
Unmanned Air Vehicles (UAVs)
April Cooke, Mechanical Engineer, Paramount Industries
3D Systems delivered an innovative design process and
manufacturing solution for the next generation of Small
Unmanned Air Vehicles (SUAVs). This work presents a
trade study between traditional manufacturing techniques
and Selective Laser Sintering for the fabrication of SUAVs.
The original SUAV design was an aircraft fabricated from
traditional carbon fiber composite material. This design was
adapted for rapid manufacturing and flight test comparison.
Composite materials (comprised of carbon fiber, Kevlar, and/or
fiberglass fabric and epoxy resins) were the baseline structural
technology for comparison. The design methods for SLS will be
discussed focusing on the implementation of conformal lattice
structures (CLS). Although the original air vehicle design was
well established, an equivalent rapid manufactured (RM) SLS
structure was qualified. The same control mechanisms were
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