Using 3D Printed Parts in Aircraft Restorations

We are developing/using 3d printed aluminium parts where I work (satellite manufacture) and have flown some smaller 3d printed aluminium components. The quality has improve massively with aluminium parts over the last few years. Airbus Civil Aircraft division have a goal of having an 80 metre by 80 metre printer (x & Y axis, not sure what Z was) by 2050 that can produce entire airframe sections according to one engineering publication. Not sure how quickly you could approve repairs to such a structure though. Some of the intricate structures I’ve seen as concept test pieces in our work would prove difficult to repair in a simple manner.

For non-load bearing parts, excellent. Beyond that I can see where questions would arise.

Already being done! As with all aircraft parts, drawing/manufacturing standards have to be adhered to, and part traceability and manufacturer approval is required, but no difference there to a ‘standard’ item.

For an airworthy part…it’s more of a matter of who makes it (and of course what’ s it made from)…rather than how it’s made.
Does it come from an authorized part maker with corresponding paperwork?

For static…anything goes.

3D part machines are coming down in price all the time. Some high-end antique auto restorers are already using them.

BAe have already flown a Tornado with a 3D printed part.

For non-load bearing parts, excellent. Beyond that I can see where questions would arise.

3D printing is already used in aircraft manufacture, and is not so expensive as imagined. You can print many items within one ‘run’, and assuming there is a need/market for these items, then it’s incredible what can be made within one finite printing volume. Printing parts inside one another (making sure they can be separated after printing!) is feasible, and waste/finishing is minimal.

It’s an exciting development and as with most technologies, the cost and trickle-down to other areas is inevitable.

With Bakelite being expensive to reproduce nylon and other resins being used as a printing medium 3D parts will become the norm in kind..The other way I have used it is as a casting master for aluminium.Have been successful with a spitfire canon spade grip and also a tube casting end for a Hawker Demon project using 3D that way..
With original parts becoming scarce I think leave the good parts for the fliers and collectors and static aircraft can use facsimiles that fill the hole..
I,m flat out designing rare and expensive parts that are impossible to find anymore.Here are some CAC Boomerang ammo counters I did for a few guys and also some Spitfire stuff for our MkV project[ATTACH=CONFIG]234368[/ATTACH]
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I had these 3D Printed for a P40 Panel a friend drew them up and placed them on Shapeways. The original mount was manufactured from a material called Tenite which is a flexible plastic So do them in black plastic was a good alternative.

Cheers,
Ash.

Very likely, Mike! Although a lot of defence companies are looking in that direction. Someone once said to me “it’s fine for Missiles as they are single use!”

It can, however, be useful for pattern making or other prototyping operations. In the world of steam engines, much use is being got out of polystyrene foam patterns that are CNC machined and then “lost foam” cast.

I would think that going to the CAA with a proposal to use 3D-printed parts in an airworthy restoration would result in an interesting, if extremely short, conversation.

Why would you print a frame? It would be astronomical in cost and I doubt very strong due the way the material is laid down. I would have thought laser cutting or CNC routing would be the way to go on that.

Agreed, 3D printing is expensive, but the cost is coming down. Let’s for example imagine someone is restoring to flying condition a Defiant or Whitley or whatever. The restorer needs to replace several fuselage frames. These would normally be handmade. This is an expensive process. Maybe a single fuselage frame might cost £10,000. Using 3D print technology might reduce the costs, and therefore make the project more doable? Or do we still live in an age were money is no option?

Jigs and complicated drilling guides can be made very quickly and incredibly accurately. However it’s expensive!