Lightweighting
Bike Manufacturer Uses Additive Manufacturing to Create Lighter, More Complex, Customized Parts
Titanium bike frame manufacturer Hanglun Technology mixes precision casting with 3D printing to create bikes that offer increased speed and reduced turbulence during long-distance rides, offering a smoother, faster and more efficient cycling experience.
Angela Osborne
Managing Editor, Gardner Business Media
BMW Expands Use of Additive Manufacturing to Foster Production Innovations
The BMW Group is manufacturing many work aids and tools for its own production system using various 3D printing processes, with items such as tailor-made orthoses for employees, teaching and production aids, and large, weight-optimized robot grippers, which are used for such things as carbon fiber-reinforced polymer roofs and entire floor assemblies.
Read MoreWill the Successes of NASA’s RAMFIRE Project Lead to an Operational Aerospike Engine?
NASA’s RAMFIRE project has additively manufactured a 36-inch diameter aerospike nozzle with complex integral coolant channels for a more efficient way to propel rockets to outer space. NASA engineers will use this as a proof of concept to inform future component designs.
Read MoreFrom Elementum 3D: Will NASA’s RAMFIRE Project Lead to an Operational Aerospike Engine?
This chronicle from Elementum 3D describes the success of NASA’s RAMFIRE project which additively manufactured a 36-inch diameter aerospike nozzle with complex integral coolant channels for a more efficient way to propel rockets to outer space. Engineers plan to use this as a proof of concept for future component designs as NASA reimagines rocket engine technology.
Read MoreLarge-Volume VFGF 3D Printer Produces Modular Helicopter Cockpit Simulator
The Queen 1 VFGF system from Q.BIG 3D produced a complete modular helicopter cockpit simulator in just over a month, all while offering high surface quality, fast build rates and lightweight construction.
Read MoreAM 4 AM’s HiperAL Aluminum Alloy Offers Enhanced Mechanical Properties for Lightweight Applications
The high-performance aluminum alloy has been specifically designed for additive manufacturing and is well suited space, aeronautic and automotive lightweight applications.
Read More3D Printed Tennis Racket Serves a Collaborative Win
The collaboration between All Design Lab and Protolabs led to the creation of a 3D printed tennis racket via direct metal laser sintering, called Hìtëkw. This project not only pushed the limits of additive in terms of design capabilities but revealed how important active communication between customer and manufacturer can be for a project’s success.
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CRP USA Creates Lighter, More Durable Paralympic Racing Gloves for Improved Performance
Paralympic champion with 20 medals, including eight golds and 24 World Major Marathon wins, looked to 3D printing service provider to create wheelchair racing gloves that can withstand the intense stress of wheelchair racing while providing the necessary precision and comfort.
Angela Osborne
Managing Editor, Gardner Business Media
Sidus Space Successfully Launches LizzieSat Hybrid 3D-Printed Satellite
The hybrid 3D-printed satellite was manufactured using Markforged 3D printers for parts that would be incredibly lightweight, durable and custom to the structure to ensure the satellite remains intact during launch and works properly for its full life span in space.
Read MoreHorizon Demonstrates Effectiveness of HMT-Metal Coating Process for Plastic Micro Additive Manufacturing Parts
The ability to make mm-wave components via micro-additive manufacturing enables the production of smaller and lighter weight components, and also opens up the possibility of making them with properties and geometric features impossible using alternative fabrication processes.
Read MoreSpherene Creates Metamaterial with Geometry Derived from Spheres
An algorithm developed by Spherene Inc. generates Adaptive Density Minimal Surfaces (ADMS) as a self-supporting infill strategy that can be used to reduce mass and manage material properties in 3D printed parts.
Read MoreTitanium Golf Club Line Leverages AM to Boost Clubhead Performance
Japanese lifestyle golf brand Designer utilizes Farsoon 3D printing to optimize the design and production of its latest titanium golf club line.
Read MoreLithoz, ORNL Partner to Advance Processing for High-Temperature Ceramics
The new process could enable laser slurry drying of non-oxide ceramics with high refractive indexes
Read MoreIndyCar's 3D Printed Top Frame Increases Driver Safety
The IndyCar titanium top frame is a safety device standard to all the series' cars. The 3D printed titanium component holds the aeroscreen and protects drivers on the track.
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Video: For 3D Printed Aircraft Structure, Machining Aids Fatigue Strength
Machining is a valuable complement to directed energy deposition, says Big Metal Additive. Topology-optimized aircraft parts illustrate the improvement in part performance from machining as the part is being built.
Peter Zelinski
Editor-in-Chief, Additive Manufacturing
America Makes Awards $3.2M for Delta Qual Project Winners
The project call winners are tasked with creating qualified additive manufacturing (AM) processes that offer rapid and affordable flexibility in crucial processes, postprocessing and material feedstock variables, while efficiently validating a qualified AM material through statistical analysis.
Read More3D Printed Lattice for Mars Sample Return Crash Landing: The Cool Parts Show Bonus
NASA Jet Propulsion Laboratory employs laser powder bed fusion additive manufacturing plus chemical etching to create strong, lightweight lattice structures optimized to protect rock samples from Mars during their violent arrival on earth.
Read MoreThis Drone Bird with 3D Printed Parts Mimics a Peregrine Falcon: The Cool Parts Show #66
The Drone Bird Company has developed aircraft that mimic birds of prey to scare off problem birds. The drones feature 3D printed fuselages made by Parts on Demand from ALM materials.
Read More8 Cool Parts From Formnext 2023: The Cool Parts Show #65
New additive manufacturing technologies on display at Formnext were in many cases producing notable end-use components. Here are some of the coolest parts we found at this year’s show.
Read MoreAvio Utilizes Velo3D Metal Printers for Developing Propulsion Systems
The Italian space propulsion innovator is installing the printers in its Colleferro, Italy, headquarters to produce mission-critical parts for its family of rocket engines.
Read More6K Additive, Agile Space Industries Partner to Advance Moon Mission
6K Additive’s Nickel 625 powder is being qualified for use in Agile’s A2200 engine to leverage additive manufacturing for engine lightweighting while also delivering tremendous power.
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Video: Orbit X Pro Football Helmet Uses 3D Printed Lattices
The lightweight helmet from Xenith will be used by NFL and collegiate football players beginning in fall 2024.
Stephanie Hendrixson
Executive Editor, Additive Manufacturing
AddUp Adds Constellium’s Aheadd CP1 Aluminum Alloy to Material Portfolio
The Aheadd CP1 aluminum alloy was developed by Constellium for the needs of additive manufacturing by laser powder bed fusion specifically for high-performance and lightweight applications.
Read MoreVelo3D Founder on the 3 Biggest Challenges of 3D Printing Metal Parts
Velo3D CEO and founder Benny Buller offers this perspective on cost, qualification and ease of development as they apply to the progress of AM adoption in the future.
Read More3D Printed "Evolved Structures" for NASA Exoplanet Balloon Mission: The Cool Parts Show #61
Generative design creates stiff, lightweight brackets for EXCITE mission monitoring planets orbiting other stars. The Cool Parts Show visits Goddard Space Flight Center.
Read MoreXtellar Offers Flexible Bio-Based EVA Pellets for Large Format 3D Printing
Bio-based flexible EVA (Ethylene Vinyl Acetate) pellets offer sustainable, lightweight, flexible capabilities for large-format additive manufacturing.
Read MoreSustainability in Additive Manufacturing Is a Moving Target: AM Radio #37
Assessing 3D printing as a sustainable manufacturing method is a complex problem. Dr. Tim Simpson and Stephanie Hendrixson discuss current research and future opportunities on AM Radio.
Read MoreHexagon Invests in Divergent’s Autonomous, Sustainable Manufacturing
The Divergent Adaptive Production System (DAPS) is a fully integrated software and hardware solution, creating a complete modular digital factory that combines AI-optimized generative design software, additive manufacturing and automated assembly to build lightweight automotive parts and frames.
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