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BOE 011911-058 Public Release Copyright © 2012 Boeing. All rights reserved.
Michael Hayes
Boeing Research and Technology
The Boeing Company
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The Future of Additive Manufacturing in Aerospace
- Where we are going, we don’t need roads-
Trends in Advanced Machining,
Manufacturing & Materials
September 12-13, 2012
Chicago, IL
Engineering, Operations & Technology | Boeing Research & Technology Manufacturing Technology
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Objectives
Part(s)
What is Additive Manufacturing (AM)?
Why does Boeing care about AM?
Where is AM today within Boeing?
Where is AM going within Boeing?
Copyright © 2012 Boeing. All rights reserved.
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Objectives
Part(s)
What is Additive Manufacturing (AM)?
Why does Boeing care about AM?
Where is AM today within Boeing?
Where is AM going within Boeing?
Copyright © 2012 Boeing. All rights reserved.
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What is Additive Manufacturing (AM)?
Additive
Manufacturing
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Part(s)
What is Additive Manufacturing (AM)?
Additive
Manufacturing
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Part(s)
What is Additive Manufacturing (AM)?
Additive
Manufacturing
FDM
SLA
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Part(s)
What is Additive Manufacturing (AM)?
Additive
Manufacturing
FDM
SLA
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What is Additive Manufacturing (AM)?
Additive
Manufacturing
FDM
SLA
Copyright © 2012 Boeing. All rights reserved.
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Part(s) Stratasys
Mojo Stratasys
Fortus 900mc
Increasing Cost
Increasing Capability
e.g. Size, Materials
What is Additive Manufacturing (AM)?
Low Cost Desktop Higher Dollar Standalone
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Part(s) Stratasys
Mojo Stratasys
Fortus 900mc
Increasing Cost
Increasing Capability
e.g. Size, Materials
What is Additive Manufacturing (AM)?
Low Cost Desktop Higher Dollar Standalone
3D Printing Additive Manufacturing
Increasingly blurring
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What is Additive Manufacturing (AM)?
Additive Manufacturing (AM) Definition
The process of joining materials to make objects from 3D model
data, usually layer upon layer - ASTM F42
CAD Model Machine
Part(s)
One Machine – One Process – Multiple Applications Copyright © 2012 Boeing. All rights reserved.
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Objectives
Part(s)
What is Additive Manufacturing (AM)?
Why does Boeing care about AM?
Where is AM today within Boeing?
Where is AM going within Boeing?
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Why Does Boeing Care About AM?
1. Weight
2. Cost
Given that a system will meet all performance requirements including
high safety considerations……..
What is important to the Boeing design engineer?
1. Cost
2. Weight
First…..
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Why Does Boeing Care About AM?
1. Weight
2. Cost
1. Cost
2. Weight
Additive Manufacturing has the potential to reduce both
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Why Does Boeing Care About AM?
Part(s)
How?
One example…. Combining multiple parts into one
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Why Does Boeing Care About AM?
Part(s)
How?
One example…. Combining multiple parts into one
Weight
Less parts
Unitization
Structural efficiency
Cost
Less parts (reduced assembly time)
Unitization
Structural efficiency
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Why Does Boeing Care About AM?
How?
Lead Time to Product One example….
No tools required
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Why Does Boeing Care About AM?
How?
Lead Time to Product One example….
No tools required
Design
Analysis
Manufacturing
Due to digital capability –
Design & Analysis are faster than ever before
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Why Does Boeing Care About AM?
Part(s)
How?
Lead Time to Product One example….
Flying Prototype
Vehicle
36 mo
24 mo
18 mo
Design
Analysis
Manufacturing
Pressure is on Manufacturing
…next step is to also embrace digital capability
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Objectives
Part(s)
What is Additive Manufacturing (AM)?
Why does Boeing care about AM?
Where is AM today within Boeing?
Where is AM going within Boeing?
Copyright © 2012 Boeing. All rights reserved.
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Where is AM today within Boeing?
Part(s)
CNC Machining (Subtractive)
1930 1950 1940 1970 1960 1980 2000 1990 2010
NC Machine
Invented
Robotic process
reaches
manufacturing
maturity
Applied across
multiple
industries
Take one step back…..
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Where is AM today within Boeing?
Part(s)
Composites
1930 1950 1940 1970 1960 1980 2000 1990 2010
NC Machine
Invented
Robotic process
reaches
manufacturing
maturity
Applied across
multiple
industries
Fiberglas
Patented
Carbon Fiber
production
begins
All fiberglas
aircraft;
H-301
Dragonfly
787
commercial
aircraft first
flight
CNC Machining (Subtractive)
Take one step back…..
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Where is AM today within Boeing?
1930 1950 1940 1970 1960 1980 2000 1990 2010
NC Machine
Invented
Robotic process
reaches
manufacturing
maturity
Applied across
multiple
industries
Fiberglas
Patented
Carbon Fiber
production
begins
All fiberglas
aircraft;
H-301
Dragonfly
787
commercial
aircraft first
flight
entire history of
RP/AM
First
production
SLS nylon
ECS ducts
Composites
CNC Machining (Subtractive)
Take one step back…..
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Where is AM today within Boeing?
Part(s)
How it is used today…..
• 200 different part numbers on 10 production platforms
• Tooling on more than 15 programs
• Prototypes
Parts are system components and are all non-structural, non-flight critical
Tooling is across the board – forming, shop aids, drill templates, assembly,…
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Objectives
Part(s)
What is Additive Manufacturing (AM)?
Why does Boeing care about AM?
Where is AM today within Boeing?
Where is AM going within Boeing?
Copyright © 2012 Boeing. All rights reserved.
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Where is AM going within Boeing?
Part(s)
Structural & Multifunctional Components
Where does Boeing want AM to go…..?
…not just limited to sub-system parts…
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Where is AM going within Boeing?
Part(s)
• Larger build sizes
• Multiple materials
• Process Control & Feedback
• Design & Analysis Tools
• Reliability
What is needed?
Structural & Multifunctional Components
Where does Boeing want AM to go…..?
…not just limited to sub-system parts
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Additive Manufacturing (AM) Definition
The process of joining materials to make objects from 3D model
data, usually layer upon layer - ASTM F42
CAD Model Machine
Component(s)
One Machine – One Process – Multiple Applications
Where is AM going within Boeing?
?
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Where is AM going within Boeing?
Part(s)
So that….
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Where is AM going within Boeing?
Part(s)
THANK YOU !
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