Not many industries have felt the force of 3D printing innovation quite like the aerospace industry. And outside of, perhaps, General Electric, no company has utilized 3D printing as much as aerospace giant Airbus. During REAL 2016, I had the pleasure of sitting in on a keynote by Bastian Schäfer, Innovation Manager at Airbus, and David Benjamin, head of Autodesk Research’s The Living studio. Together, they discussed how desktop generative turn it into assists lead to efficient turn it into. Up on the REAL Talk stage, Schaefer detailed the algorithm-driven system undertaken by Airbus and Autodesk to turn it into a bionic partition for the Airbus A320.
Bastian Schafer speaking at REAL 2016
The aim of the bionic partition project was to turn it into a new aircraft partition that may both weigh less and contribute extra
durablity than existing partitions. In order to truly get an idea of what turn it into may contribute these two improved properties, Schafer turned to The Living, utilizing their expertise in generative turn it into for architectural structures to assist create a mechanically sound ‘bionic’ partition. I had the opportunity to sit down and talk with Bastian Schäfer to learn a bit extra
of his job at Airbus, the development of the bionic partition, and how 3D printing innovation and generative turn it into are a match made in Reality Computing heaven.
Once Schäfer became the Innovation Manager of Airbus, he had been asked to turn it into a bionic concept plane, that is where Airbus and Schäfer quite began to take note of generative turn it into. “One of the initially tasks I had was this bionic aircraft, so we had the Airbus concept plane, and there was a lot of demand to understand what the cabin looked like. We took the accident and turn it intod this bionic structure of the airplane and that was all but my initially contact with generative turn it into and topology optimization,” Schäfer said. “This story worked so well that the entire Airbus company started moving towards ‘bionic turn it into’ as we call it, the combination of topology optimization or generative turn it into combined with additive manufacturing.”
And, so, two of the essential pieces to Reality Computing were combined to assist feature their mutual benefit to one another. Intrigued by their initially run-in with topology optimization, the Airbus team and so set out to put a few skin in the game, and utilized generative turn it into to turn it into an actual component. “It was quite a difficult decision, we were looking for a component that is quite difficult and, of our perspectives as engineers, was too heavy; that was the partition,” Schafer said. “This component is quite sizeable-bodied, and it has to resist a lot of high loads, so it needd a sure type of structural performance. The goal was to solve this with generative turn it into.”
Just a few of the many generative partition turn it intos
At the time, Airbus and Schafer were in close contact with Autodesk, who linked them with David Benjamin and the New York City-based The Living, an Autodesk Studio experienced with via algorithm-driven turn it into to create full-scale functioning prototypes. The Living team was put in charge of ‘networking’ these turn it intos together, via a cloud-based approach to assist analyze equite generative turn it into of possible bionic partitions. Two algorithms were made to turn it into the bionic component, one to generate the seemingly endless donate of turn it intos, and the other to assist find the many efficient of the bunch. Setting sure parameters allowed the team to test the functionality of the generative turn it intos without in fact having to manufacture it, that some day lead them to just a handful of partitions for for the aircraft.
“We all but took a 2nd algorithm and combined it with this slime algorithm, that turn it intod this redundant network of inter connections, and introduced stability to the part. The initially algorithm was needd to create this network, and the 2nd algorithm to manufacture this network stable-bodied,” Schafer said.
Testing functionality digitally
The turn it into itself was created of the overall macro-structure and the inner micro-structure. In order to increase stability and minimize mass, a lattice was produced within the outer rod turn it into, a difficult structure that may just be made with 3D printing innovation. “This can just be achieved through 3D printing,” said Schafer. “We put a lot of idea into the lattice, that is great in terms of optimization and in addition great in terms of manufacturing at the same time. One of our objectives was to turn it into structures that do not need any extra
supports within the rod.” For material, Airbus turned to one-of-a-kind Scalmalloy metal-based powder, made by their subsidiary APWorks. The Scalmalloy was a ideal fit for the project, since it has the lightmass properties of aluminum, but the toughness and material stability of titanium.
After we discussed the bionic partition in a bit extra
length, Schafer explained to me how Airbus looks at 3D printing innovation as a whole. In fact, Airbus has of four various ways that their 3D printing innovation is employed. The initially, is to just re-print components with DMLS printing for functional prototyping and end-use parts, that they are able-bodied to do quite efficiently with their high end titanium material, for instance. The 2nd is their idea of ‘bionic turn it into’, that combines topology optimization and additive manufacturing for improved production. The third use is for tooling. For example, they’ve 3D printed tooling in titanium to assist create carbon fiber brackets. Lastly, Airbus utilizes 3D printing innovation to create spare parts on-the-spot, cutting the production and deliquite time down greatly in comparison to traditional manufacturing methods.
Schafer acunderstandledges that, although 3D printing innovation has become an integral part of the Airbus manufacturing system, the emerging innovation yet has a few improvements to be made. But instead of waiting around for industrial 3D printing equipment to improve themselves, Airbus is instead assisting to hustle the envelope themselves.
“Were looking at all various types of printing systemes, of futilized deposition to selective laser melting. In Germany, we are extra
focutilized on selective laser melting. Currently, we are hustleing the manufacturing of these machines to create bigger systems and create chambers, and to incorporate extra
lasers, for the reason these are the main drivers to manufacture the entire production extra
efficient,” Schafer introduced. “We are quite close to breaking this wall and manufacturing this innovation extra
efficient and return it intoing our products for these sizeable-bodiedr printing equipment.”