Through aerodynamic optimization of design and reduction of drag, aerospace components printed with SLS technology can save 4% of fuel

》Challenge:
Deliver a strictly controlled patented design in a short period of time, from prototype production to production of parts, including necessary inspections and reports
》Solution:
3D Systems' on-demand manufacturing service expert Quickparts, SLS selective laser sintering technology, glass fiber filled nylon material DuraForm GF
》Result:
• Deliver 18 production-grade satellite blade sets and 360 components within two months
• Successful First Article Inspection & Report
• For future needs, parts of the same quality and performance can be manufactured repeatedly
• Customer satisfaction is high, and the components have passed the AS9100 quality system (AS9100 is an aerospace standard developed on the basis of ISO 9001 quality system requirements)

▼▼▼ In the aviation industry, even the slightest design change can have an amazing impact on flight efficiency. This is why aviation manufacturers have persistently invested a lot of time and labor costs to optimize the design of flight equipment.
Sometimes, a little modification can bring huge rewards, like the 3D printed miniature blades produced by Metro Aerospace, Texas, mentioned below. This part is specially developed for the C-130/L-100 aircraft. The blades will be tightly fixed on both ends of the fuselage, mainly to reduce drag by changing the airflow of the rear cargo door.
▼▼▼ 3D Systems' on-demand manufacturing Quickparts team helped Metro Aerospace convert miniature blades from prototypes to production parts at an extremely fast rate. 3D Systems' on-demand manufacturing expert Quickparts can provide component support at any stage of product development, providing rapid prototyping, demonstration models and small batch production of components.
3D Systems' on-demand manufacturing division Quickparts in Tulsa, Oklahoma uses selective laser sintering (SLS) and nylon fiberglass material DuraForm GF (suitable for making durable prototypes or small and medium-volume parts with strong rigidity and high temperature resistance) and Metro Aerospace successfully completed the first inspection report. This verifies that all manufacturing requirements and component specifications are produced in strict accordance with the regulations through SLS equipment.

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 3D printed parts help aircraft reduce drag and cost

The 3D printed miniature blades are each about 10 inches (25.4cm) long, and each blade can be different. According to Metro Aerospace, these 3D printed engineering accessories can reduce the total drag of the aircraft by 15%.

Metro Aerospace pointed out that the structural combination of these components can significantly reduce internal test engine wear while reducing fuel consumption by approximately 25-30 gallons per hour. Although it is a small change, for the aircraft, even a small change can have a significant impact.

For commercial aircraft, SLS printed miniature blades greatly improve fuel efficiency; for military aircraft, this helps them extend the flight time and load capacity of missions. For these applications, there are huge advantages.
Mini blades can be installed on new aircraft, and can also be easily modified without any structural changes to the aircraft. Apart from the expected drag reduction effect, it will not have any impact on the operation of the aircraft.
Leslie Peters, President & CEO of Metro Aerospace, said: Procurement and installation of micro blades, based on the achievable fuel savings, can quickly pay off within a year.
The rapid return on investment, ease of installation and minimal impact on the aircraft also have significant cost improvements for large cargo aircraft.
For Metro Aerospace, the use of 3D printing for production and collaboration with the on-demand manufacturing team of 3D Systems allows Metro Aerospace to eliminate the need for excessive storage of accessories, but does not affect the fast and high-quality completion of customer orders.
▼▼▼ Excellent experience based on 3D printing

Metro Aerospace chose 3D Systems because of its professional experience and leading technology based on additive manufacturing. Peters of Metro Aerospace mentioned: "Additive manufacturing technology is a relatively new technology, and it is also a new method for mass-production of aircraft external parts."

Through 3D Systems' familiarity with the aviation industry and the experience in the stage of producing miniature blade prototypes, Metro Aerospace quickly transitioned the miniature blade from prototype to production part. Peters pointed out that transforming prototypes into final parts is not a simple matter, especially in the aviation industry. She said: "This is not as simple as people think. It is not a simple handover. It involves many aspects."
The final 3D printed miniature blade must meet the strict design intent of the engineers, and must pass the first inspection report, because this is a general requirement of the aviation industry.
3D Systems and Metro Aerospace worked closely together throughout the entire process, from printer and material testing to component labeling, completion to transportation, ensuring that every detail was given full attention. The two parties also worked together to meticulously record the control documents of the entire process and verify how to meet the strict requirements of the new product.
Peters said that 3D Systems is not slacking in every aspect: "Sometimes it takes 6 months for the first inspection report alone before starting manufacturing, but this time we cooperated with 3D Systems in 3-4 months. Within time, our report was passed and the product was delivered to a foreign military enterprise. As far as the aviation market is concerned, this is really fast."
▼▼▼ Proven aviation industry experience
In a very urgent time, through a wealth of experience, 3D printing has been truly transformed into 3D production.

Certified by ITAR (International Arms Trading Regulations) and AS9100 (aerospace standards developed on the basis of ISO 9001 quality system requirements), 3D Systems' on-demand manufacturing center in Tulsa, Oklahoma has been demonstrated by high-quality prototypes It is perfectly feasible to make precise final parts in small batches.

The production of high-quality aerospace components involves the use of multiple manufacturing techniques, and 3D printing is no exception. The 3D Systems team collaborated with Metro Aerospace to verify the feasibility of the SLS printer, performing tensile and density tests through internal and third-party tests, and testing in accordance with the standards required for miniature blades.
Peters mentioned: "You need special equipment, special rooms, and a qualified company to manage all processes and products. "Have the right documents and processes, use 3D Systems' on-demand manufacturing services to complete orders, and the entire process is streamlined. And efficient, so Metro Aerospace can quickly respond to customer needs.
▼▼▼ 3D printing production capacity and full service
The speed at which products can be brought to market is critical to Metro Aerospace, and 3D Systems’ equipment and capabilities make fast delivery a reality.
From beginning to end, the on-demand manufacturing team of 3D Systems has improved the quality and production efficiency of parts through open and transparent communication, and is dedicated to Metro Aerospace.
Peters mentioned Quickparts, a production expert at 3D Systems: "They are really very responsible and dedicated. When we want to accomplish something, they are also working for us on weekends."
The success of the miniature blades printed by SLS technology gives Metro Aerospace a direction for further exploration of 3D printing.
In order to ensure that the design of the mini-blade attachment is foolproof, Peters once again cooperated with the on-demand manufacturing department of 3D Systems to bring this component to the market. Prior to this, they had accumulated a wealth of experience through the production of the mini-blade.
Whether you need to quickly get 3D printed parts, post-processed assembly prototypes, demonstration models, or small batch parts processed by CNC/polyurethane casting/injection molding, the 3D Systems on-demand manufacturing department will help you promote project progress and complete R&D on schedule And reach the set goals.