Dear Professors/Researchers,
Can you please suggest, the latest Additive Manufacturing & Casting Techniques used for Aerospace Applications?
Among Additive Manufacturing (AM) techniques which are gaining increasing interest in aerospace industry there is Big Area Additive Manufacturing (BAAM).
It is also known more generally as Fused Granular Fabrication (FGF) or Pellet Additive Manufacturing (PAM).
In these techniques a single-screw extruder similar to the ones being used in plastic extrusion industry is used to selectively deposit thermoplastic materials layer-by-layer, as in conventional Fused Filament Fabrication (FFF) techniques.
The main advantages of BAAM are related to:
- large format (printing volumes up to 7 meters cube)
- high range of materials (e.g., fiber reinforced, bio-derived and recycled)
- energy savings (no need to print with an heated chamber, if carbon fiber are used as reinforcing material)
- reduced lead times (which is critical for aerospace) and material wastes
More considerations on the advantages of BAAM over FFF have been made in the following articles:
A generalized method aiming at predicting the polymer melt flow field in the metering zone of large-scale single-screw extruders
https://www.researchgate.net/publication/378851077_A_generalized_method_aiming_at_predicting_the_polymer_melt_flow_field_in_the_metering_zone_of_large-scale_single-screw_extruders
Analytical and Numerical Models of Thermoplastics: A Review Aimed to Pellet Extrusion-Based Additive Manufacturing
https://www.researchgate.net/publication/354758555_Analytical_and_Numerical_Models_of_Thermoplastics_A_Review_Aimed_to_Pellet_Extrusion-Based_Additive_Manufacturing/stats
BAAM has been successfully applied to produce molds for horizontal axis wind turbines:
https://www.ornl.gov/sites/default/files/2019-06/web_Hover_Final_Report.pdf
A second technique is Electronic Beam Additive Manufacturing (EBAM), which has been applied to manufacture large satellites:
https://3dprinting.com/metal/ebam-used-for-large-satellite-structures/
Best regards,
AP
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