Inside the Boeing 787 Dreamliner display at the Future of Flight.
This is how Stefan of SLM Solutions GmbH and I roll, uber first class. He traveled all the way to Seattle, Washington from Germany to learn about Boeing’s manufacturing operations. Of course I had to tag along for my gazillionth trip to the Future of Flight. My main-gal-awesome-marketing-manager at the Future of Flight was able to sneak us behind the construction lines to pose for a photo (above). Clearly always pays to have good friends in marketing as the aviation museum was closed that day due to a massive renovation project. If you haven’t been, it’s a must see in the Seattle area and while you are there, be sure to take the Boeing Factory Tour. It is amazing!
Did you know that the materials used in the 787 Dreamliner are tougher and lighter than aluminum? I guess ya, you probably do and I’m singing to the choir if you’re reading my blog. But in case you’re new, composites are materials made of two or more components. They are often used in high-performance products, where materials need to be lightweight, yet strong enough to take sever leading conditions, from airliner wings to competition skis and snowboards and from Formula One racing cars to fly fishing rods.
Look ma no hands, I'm in the 787 Aft Fuselage Test Piece COPB2 display at the Future of Flight.
As an example, the Boeing Dreamliner is composed of 50% composites, which are combined of woven carbon fiber threads impregnated with specialized resins. The unique material used in construction of the Composite One Piece Barrel, (test piece two shown right) for the Boeing 787.
Key Innovations:
- Reduction of 1,500 aluminum sheets
- 40,000 – 50,000 fewer fasteners
- Cabins designed for a more comfortable air pressure for passengers
- An increase in the cabin’s relative humidity because composites are not as subject to corrosion
- The strength of composites allows for larger windows
- Improved fuel consumption due to the lighter airframe
- Reduction use of hazardous chemicals, and less hazardous waste
- Reduction in overall waste of materials
Boeing… YOU ROCK. I love to fly, I love things made in America. Also really cool to note, some of my favorite peeps work at Boeing in Research and Development, Rapid Prototyping and Additive Manufacturing. These guys really know how to make these things happen.
Okay now, back to composites… There are a lot of companies out there in the Additive Manufacturing industry who work with these every day.
Aeorspace Components manufactured at Paramount Industries in Pennsylvania.
Paramount Industries processes several different base materials for Selective Laser Sintering — enhanced with proprietary processes like Conformal Lattice Structures (CLS), nano composite technology and High Temperature Laser Sintering for high profile projects in aerospace, for examples the F-35 Joint Strike Fighter Program. So that’s the scoop with Paramount, they build parts for airplanes, primarily in plastics that perform like metals via Selective Laser Sintering. They run a variety of plastics on 3D Systems, OES and DTM equipment. If you’re looking for a reliable source for prototypes and production parts, contact Paramount Industries.
Production Part manufactured with SLM Solutions' Selective Laser Melting System 125 HL.
If you’re looking to buy a Laser Sintering system, contact any of the above named manufacturers (3D Systems, EOS) or SLM Solutions, a Laser Melting technology manufacturer. The company builds equipment that processes metal powders with Selective Laser Melting. Their new compact Selective Laser Melting System 280 HL builds highly complex metal components using fine metal powders from 3D CAD data files (ala additive manufacturing via 3D printing). SLM’s 280 HL is suitable for R&D, prototyping and production at companies like Boeing, Airbus — anything from aerospace, automotive and marine to medical device and surgical implant manufacturers. It builds parts in most metals: stainless steel, tool steel, cobalt-chromium, inconel, aluminum and titanium. Highlights:
- patented new bidirectional loader movement
- heated build platform
- safe filter system highly efficient protective gas consumption
There are specifics differences about Selective Laser Sintering and Selective Laser Melting technologies guaranteed to interest manufacturing engineers. Paramount Industries (Pennsylvania-based service bureau) and SLM Solutions (Germany-based original equipment manufacturer) can explain to you the differences.
Do you build plastic or metal prototypes and production parts for world-class manufacturers? Tell me about it.
Submitted by: Nadra Angerman
Angerman Communications Group
Follow on Twitter @NadraAngerman & @thejetcitywoman
October 3, 2011
Additive Manufacturing, Nadrafied, Technology