Tool-free production with a 3D extrusion printer opens up short time-to-market strategies for users. Eliminating tooling costs and utilizing new build strategies for component geometries combine with extremely short amortization periods for this system technology. The special feature of this technology, compared to alternative AM strategies such as FDM printers, is the use of commercially available standard granulate without filaments in 3D printing.
Development project of a 3D cockpit
The aim of the Reiser helicopter cockpit development project at Murtfeldt AS was to overcome previous limitations of conventional manufacturing strategies by a contemporary VFGF strategy for large 3D parts. Classic mold-based processes, especially for large-volume components, incur high tooling costs and long lead times.
Reiser Simulation and Training, in Berg near Starnberg, Germany, commissioned Murtfeldt Additive Solutions (Murtfeldt AS) in Kusterdingen, Germany, to produce a modular cockpit for a full-flight helicopter simulator. The cockpit was made on a Queen 1 system from Q.BIG 3D at Murtfeldt.
3D cockpit module manufactured at Murtfeldt Additive Solutions. Image courtesy of Q.BIG 3D, Backnang, Germany.
Murtfeldt AS used a partially aromatic polyamide with 25% glass fiber content (Q.mid GF25) for the cockpit frame. With 0% lengthwise and 0.2% crosswise fibers, this material has particularly high dimensional stability, high temperature stability (up to 200°C), high stiffness, and excellent paintability. Q.mid GF25 is qualified for numerous fields of application.
Large-volume 3D extrusion printing redefined: The variable nozzle contributes to build speeds, high surface quality, and dimensional accuracy with constant gap dimensions. Image courtesy of Q.BIG 3D, Backnang, Germany.
The solution was additive manufacturing on a Queen 1 machine from Q.BIG 3D, available at Murtfeldt AS for oversized 3D components. According to the companies involved, such a project can be completed in 3–6 months. In addition, conventional fused deposition modeling (FDM) printers usually can’t produce large-volume 3D components, have uneconomical build rates, and use material containing filaments, which are often seven times more expensive per kilogram compared to a granulate 3D printer.
However, Murtfeldt AS expects shorter build times for a follow-up project by optimizing the process chain. A printer network comprising several Queen 1 machines can also shorten the delivery time for time-critical requests. The longest single build job was almost 100 hours.
Last but not least, functional integration, such as integrated cable races, is possible, thanks to segmentation of the 3D assembly. In its entirety, there are significant price advantages for the finished assembly for suppliers and end users; moreover, the cockpit is available on very short notice.
Cockpit material
In terms of design, Reiser specified sensitive areas for the nozzle control; solid material was specified at the mounting points of the door hinges, for example. This resulted in greatly reduced build times compared to continuous nozzle use, as well as material-saving lightweight construction of the 3D components.
Conclusion
For more information about Q.Big 3D’s aerospace applications, visit www.luft-und-raumfahrt.qbig3d.de/en/.
منبع: https://www.qualitydigest.com/inside/innovation-article/murtfeldt-additive-solutions-produces-3d-helicopter-cockpit-052224.html
Johannes Matheis, managing director at Murtfeldt AS, says, “With the innovative VFGF system technology from Q.BIG 3D for large-volume 3D components, we at Murtfeldt can specifically tap into further areas of application for the VFGF manufacturing strategy. If you master the entire process chain, complex, large 3D components with high repeatability and component quality on a new level are possible.”
Michael Ortmann, of Reiser Simulation and Training, responsible for design and development, emphasizes that the advantages of 3D extrusion printing offer several potential benefits that previously didn’t seem possible. He cites “Extremely short time to market, high build speed, lightweight construction, bionics, functional integration, and cost-effective manufacturing without the need for molds, along with the merits of using granulates, to name just a few aspects.”
In addition, the control of distortion in these large and complex components, tight tolerances of gap dimensions, and high-quality surface are other highlights. Dimensional accuracy is essential for screw fastenings and precise pinning. Reassembling the demountable module at the user’s location was just as advantageous, along with the fact that two helicopter models (Airbus helicopters H135 and H145) could be cost-effectively simulated using a conversion kit.
The key feature is the variable nozzle of the Queen 1 system. The fast build rates for the Queen 1A are due to a variable nozzle control system that adapts to the particular characteristics of each geometry. Delicate areas of the components are built up in the normal nozzle mode. Large in-fill areas on the thick pillars of the cockpit, however, are created in a fast turbo mode to reduce the build duration while increasing stability. Modes change automatically on the Queen 1.
Queen 1 system from Q.BIG 3D at Murtfeldt. Image courtesy of Q.BIG 3D, Backnang, Germany.
Building a modular cockpit
An additive manufacturing (AM) strategy using the Queen 1 system technology with no tooling costs provides customers with a low investment risk while eliminating post-processing costs. Furthermore, this strategy also offers advantages over competing AM strategies, such as SLS or FDM printing, because those components often have to be glued together. This can result in disadvantages in functionality, tightness of fit, and dimensional accuracy due to imprecise tolerances.
This is a result of the well-thought-out system technology. The active temperature control of an outer chamber, as well as the build space of the Queen 1, make a stable and repeatable process possible. Temperatures of not only the build space but also the entire mechanical system are kept constant, regardless of temperature fluctuations in the production hall itself.
The Queen 1 3D extrusion printer from Q.BIG 3D produced high surface quality, even in the case of the geometry’s strong overhangs. The highly accurate fit of the components in the assembly (e.g., dimensional accuracy, small gaps) was equally impressive.
The 3D cockpit was made with additive manufacturing of all assembly components on a Queen 1 from Q.BIG 3D at Murtfeldt AS. The dimensions of the cockpit are 2,260 mm (x), 1,780 mm (y) and 1,705 mm (z). The cockpit weighs only 200 kg, since 3D printing enables a resource-saving lightweight build. Manufacturing all components took just over a month.
Additive manufacturing of oversized plastic components offers enormous advantages for mold-free small- and medium-size production runs. The key to this is Q.BIG 3D’s VFGF (variable fused granulate fabrication) process.
New level in 3D extrusion printing of large-volume components using plastic granulate. Image courtesy of Q.BIG 3D, Backnang, Germany.
The finished cockpit assembly received a final coat of flat black paint (lead time approximately two weeks) to prevent annoying light reflections in the simulator.
High surface quality, fast build rates, and lightweight construction