UNMANNED FLIGHT SYSTEMS CREATE GROWING NEED FOR LASER-SINTERING SYSTEMS
Laser-sintering equipment manufactures complex aircraft components that are impossible to create using traditional manufacturing processes. The process meets tight tolerances and requires no tooling.
Posted: September 13, 2010
The increasing use of unmanned flight systems has created a growing need in the laser-sintering industry. Many of the complex aircraft components are impossible to create using traditional manufacturing processes. Laser-sintering is the key technology for e-Manufacturing, the fast, flexible and cost-effective production of products, patterns and tools.
Northwest Rapid Manufacturing (McMinnville, OR), part of the Northwest UAV family of companies, manufactures production parts and prototypes for NWUAV using its EOSINT P 390 and P 730 equipment. EOS (Krailling, Germany) is one of the world's leading manufacturers of laser-sintering systems. Together, the companies provide parts and assemblies including engine and cooling components for unmanned aerial vehicles (UAVs) made by Insitu, Inc., and others. These components are stable in hot environments and are tough, pliable, and robust in harsh conditions such as exposure to fuel.
"Manufacturers of UAVs face stringent demands, both for part requirements and delivery schedules,? says Alexander Dick, VP of laser-sintering operations at Northwest Rapid. ?EOS laser-sintering equipment enables us to meet tight tolerances, ensure component strength and performance, and deliver parts on or before deadlines.?
?The huge growth of the unmanned-systems market has triggered a wave of innovative and unique designs,? says Udo Behrendt, key account manager, aerospace, EOS. ?Our customers are using metal and plastics laser-sintering to push the boundaries of those designs.?
Solid Concepts, who created SLS-manufactured flight structures for Aerotonomy?s new Cruise-Efficient ESTOL research aircraft, manufactures plastic laser-sintered aerospace parts from a wide range of applications and materials. In addition to the aircraft?s form-fitted seven-gallon fuel tank, all of the primary structures that enable the advanced high-lift technologies, such as leading-edge blowing, circulation-control flaps, and airflow plenums were manufactured with EOS laser-sintering equipment.
Plastic and metal laser-sintering are already widespread in UAV and other aerospace applications. In addition to producing durable, lightweight and complex parts, the technology requires no tooling, thereby reducing upfront times and costs and making re-designs and customization easy and affordable.
"On any given UAV system, once its customer and field use changes, the only features that stay the same may be the frame and most of the fuselage,? says Frederick Claus, business development manager at Solid Concepts. ?The manufacturing flexibility and speed of laser-sintering have proved their worth in this industry time and again.?
Among the materials currently available for laser-sintering of UAV components are:
? Several polyamides (including a flame-retardant material)
? EOS PEEK HP3 (a high-temperature thermoplastic polymer)
? Titanium
? Cobalt chrome
? IN718 (a nickel-chromium super alloy)
Additional materials for UAV and other aerospace applications are in development.
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