Power bed. Build chamber. Completed solid. www.engineeringnews.co.nz 33 system with a standard build plate of 280 x 280 x 365mm3 made it possible to produce a large valve body. The SLM280HL contains multi-beam technology of dual 400W lasers enabling a part this size to be built in a relatively short time frame compared to conventional manufacturing. Using conventional techniques would have meant machining the part out of a billet possibly taking several weeks. Casting a part would have taken even longer as the tooling would first have to be built. Additionally, the 3D build process only required one initial ‘set-up’, a significant reduction to the four or five set-ups required using conventional processes. Further, no operational interruptions were experienced during the six and a half days of the build reinforcing the reliability of the SLM280HL laser system and preserving costs. The SLM280HL system uses dual lasers working simultaneously and while this increased the speed of production questions were raised regarding the reliability of the sections of ‘overlap’. Subjecting these sections to tests the results showed no differences in quality between of the area built by one laser and the overlap from the other laser. Testing of parts suitable for critical use in aerospace engines may also need to undergo computed tomography (CT) to check for porosity or internal voids, or they can even be subjected to destructive testing where the product is simply pulled apart! Such are the stringent regulations that must be met by all international manufacturers participating in the supply of aircraft parts that selective laser melting processes (SLM) can achieve. Taking this a step further, while the original part may be developed close to the point of aircraft manufacture, the CAD design and acquired knowledge of 3D production is transferable via secure communications to relevant providers with 3D manufacturing capability, to be part of the supply chain anywhere in the world. Contracts by local manufactures to build ‘just-in-time’ parts can be produced on a needs basis close to the point of requirement, reducing time to service and removing shipping costs. A further example of design capability was seen in 2016 where GE Aviation was able to produce a fuel nozzle for the CFM Leap engines used in the Airbus A380 as a single part, reducing the normal complex production process of making and joining 18 different parts together that performed one operation. By exploring and testing part functionality, the company has reduced part count, a real cost efficiency gain as well as a making significant step forward. The single light weight, 3D printed fuel nozzle has now been put into service revealing durability 5 times that of the conventionally manufactured part, a further testament to the reliability of 3D part production. GE engineers have broken new ground by producing a part that could not have been done before and opening the way for the re-examination of part counts in all industries where mechanical properties are critical to functionality. As we have seen being able to transfer a design by the cyber-physical network for localised production reduces time to service while eliminating freight cost. It is this process that will bring about change to manufacturing as well as to the future role of the supply chain enabling manufacturers who want to participate, the opportunity to join Industry 4.0. EN093 KNOBS & HANDLES Extensive range in stock, fast delivery • Knobs & handles • Handwheels • Levers • Adjustable feet H_2370 Available from Hi-Q Electronics Limited engineering@hiq.co.nz 0800 766 709 www.hiqknobs.co.nz
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