意大利国防承包商伦纳多is working with UK based engineering companySFM技术和大型3D打印机制造商BigRep，到3D打印密钥组件皇家海军奥古斯特兰AW101直升机。
When being stored and transported on ships, the helicopters fold their blades up to make them more compact. A main rotor blade restraint cradle is used to stabilize the rotors, and prevent them from flapping in the wind. Leonardo found that their pre-existing restraint cradles weren’t living up to the required standards, and turned to SFM Technology’s AeroAdditive division to provide a solution.
通过广泛的压力测试,SFM发现3D printed parts performed better than their non printed counterparts, offering a lightweight and strong product. This new main rotor blade restraint cradle, measuring 900 x 230 x 160mm, is being billed as the first of its kind to be created using AM technology.
利用BigRep Pro打印机和Hi-Temp CF材料
In order to develop and manufacture the restraint cradles, SFM chose to leverage AM technology from BigRep. “We had a look at many aspects of 3D printing. We must look at cost, efficiency, and of course, the size, which pushed us to BigRep”, commented Gary Wilson, head of Technical Sales at SFM’s AeroAdditive division.
由于该项目所需的生产规模，SFM技术选择使用BigRep Pro 3D打印机。This industrial 3D printer has a 1 cubic meter build volume and can produce parts at scale for all stages of the manufacturing process, making it ideal for SFM’s end-use part requirements. “We looked at the BigRep Pro as we had to look at a production 3D printer, which I believe the BigRep Pro can provide”, continued Wilson. “The machine is used as a production machine, so every rotor blade restraint cradle will be going to the end user”.
BigRep Pro提供自动打印床和挤出机校准，已大大提高了SFM Technology生产过程的速度和效率。例如，自1月以来已经打印了30个由60个部分组成的摇篮，而是使用传统方法的四分之三。威尔逊说：“ 3D打印要快得多，因为我们没有任何调整可以进行的调整，或者如果这样做，它们非常小，可以很快克服。”
与BigRep Pro打印机一起，SFM利用BigRep的Hi-Temp CF CF碳纤维增强材料。这种高强度的工程型灯丝具有115℃的高热偏转温度和65 MPa的拉伸强度。由于使用了这种令人难以置信的坚硬耐用的材料，因此，约束摇篮被定义为具有强大的外部压力和磨损的抵抗力。威尔逊（Wilson）证明，进行了多项测试，以确定最合适的预算材料，而Hi-Temp具有“优于其他BigRepep材料”。
Once the print process is complete, support materials are removed and the surface is smoothed. Bushes are then inserted in the hinges, followed by the addition of helicoil inserts. Once painted to the customer’s specifications, the remaining metal parts are added along with the foam inserts on the inside of the cradle, which protect the rotor blade when the restraint cradle is fitted.
AM within the broader defense and aerospace industries
在航空航天应用中使用3D打印并不是什么新鲜事物，这不是莱昂纳多第一次利用AM技术。去年，Desktop Metal子公司Aidrocollaborated with Leonardo to supply3D打印的直升机零件。Since receiving Leonardo’s Declaration for Qualification of Process for Additive Layer Manufacturing, Aidro has begun production of flight-ready parts for Leonardo’s rotorcraft lineup. This lineup includes high-performance civil, parapublic and military helicopters.
莱昂纳多（Leonardo）有将AM技术用于航空航天应用的历史。2020年，该公司宣布正在利用它机器人Argo 500工业3D打印机以减少碳纤维生产的成本和交货时间尼龙6和窥视零件。
Away from Leonardo, it was announced in January that Chinese aerospace firm银河能正在利用3D打印来帮助制造该国最大的reusable rocket engine。来自法苏恩is leveraged to produce more than 30 3D printed parts for theWelkin 50吨LOX/煤油发动机。
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特色图显示了Agustawestland AW101。通过Leonardo直升机的照片。
