The company also builds essential
ground-running equipment on the Stratasys Fortus 450mc 3D printer
in tough Nylon 12 material at lower cost than aluminum
production
Marshall Aerospace and Defence Group is now using advanced 3D
printing from Stratasys (Nasdaq: SSYS) to manufacture, flight-ready
parts for several of its military, civil and business aircraft -
while producing specific ground-running equipment at a lower cost
than aluminum alternatives. The company is currently one of the
world’s largest privately owned and independent aerospace and
defense companies.
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Final, flight-approved, 3D printed
ducting for air conditioners. 3D printed in ULTEM™ 9085 resin on
the Fortus 450mc (Photo: Business Wire)
Marshall already has several pieces of 3D-printed ductwork
flying on heavily modified aircraft, as well as holders for safety
knives and switches for aircraft interiors. 3D printing
flight-approved parts on demand enables the company to produce
lighter parts than traditional methods, significantly faster and at
lower cost.
According to Chris Botting, Materials, Processes and Additive
Manufacturing Engineer at Marshall ADG, the ability to create
accurate, repeatable and reliable 3D printed parts using
aerospace-approved materials are key factors in achieving the
performance requirements necessary for use within aircraft.
“When manufacturing on complex engineering programs, we need a
method that can create an accurate, complex, functional and
lightweight duct efficiently with minimal tooling costs – this is
where 3D printing fits perfectly. But we also need to ensure that
the ducting work produced will be approved by the EASA for flight,”
explains Botting. “As a result, we’re using the Stratasys Fortus
450mc FDM Printer and ULTEM™ 9085 resin – a tough, yet lightweight
3D printing material with high thermal and chemical resistance.
This has been crucial to overcoming the stringent requirements of
our industry, as we can now 3D print parts with the desired flame,
smoke and toxicity properties for use on aircraft interiors.”
On the Ground Savings
The company is also utilizing its Fortus 450mc 3D printer,
purchased from Stratasys UK and Ireland Platinum Partner SYS
Systems, to build final parts on the ground. Marshall recently
created a ducting adapter prototype for vital ground-running
equipment – essential for providing fresh air to cool the
aircraft’s avionics. 3D printing this particular part helped
Marshall transition from typically costly aluminum processes.
“Before committing to expensive aluminum machining, we used the
Fortus 450mc to 3D print a prototype in ASA material,” says
Botting. “It enabled us to create an accurate working prototype of
a complex component. We were then able to demonstrate it had the
potential to be 3D printed in Nylon 12 material as opposed to the
more conventional method of machining from aluminum. The 3D printed
duct led to a significant cost reduction compared to machining the
part out of aluminum, as well as a 63% reduction in overall
weight.”
The group is also using Stratasys 3D printers for a range of
complex tooling applications, including drill jigs, masking
templates, bonded fixtures and composite mold tooling. The team
regularly produces customized, low-volume production tools within
just 24 hours of an engineer’s request. In fact, they are driving
use of 3D-printed thermoplastic tools to replace heavy metal tools,
reducing the burden on the operator, and crucially, reducing cost
and lead times on urgent operational tasks.
Botting foresees the use of Stratasys FDM additive manufacturing
to increase across all elements of the business and to drive new
applications.
“FDM technology has altered the way we work, and the
aerospace-grade 3D printers and materials enable us to meet our
increasingly aggressive deadlines and complex manufacturing
requirements,” Botting said. “In the future, there is no doubt that
3D printing will continue to have a significant impact in the way
we design and manufacture in our business.”
To learn more about Stratasys’ additive manufacturing solutions
for the aerospace industry, visit Hall 4, Stand D192 at the
International Paris Air Show, 2019, June 17th – 23rd, Paris,
France.
Marshall Aerospace and Defence Group has specialised in
protecting people in critical situations for more than 100 years.
Today the company continues to deliver world-leading applied
engineering services to a wide range of global customers, ensuring
they benefit from our agility, innovation and collaborative
approach, whatever their needs. They rely on our core capabilities
of managed services, integration and technologies, which we deliver
in partnership through the ability to solve the most complex of
challenges. We are a team of more than 1,800 highly skilled
colleagues, located across UK, Canada, Europe and UEA, dedicated to
setting the highest standards across the industry. Marshall
Aerospace and Defence Group is part of Marshall of Cambridge
(Holdings) Limited, the private holding company of the Marshall
family. Founded in 1909, the Group had a turnover of nearly £2.5bn
in 2018, and more than 6,000 employees.
Stratasys is a global leader in additive manufacturing or
3D printing technology and is the manufacturer of FDM® and PolyJet™
3D printers. The company’s technologies are used to create
prototypes, manufacturing tools, and production parts for
industries, including aerospace, automotive, healthcare, consumer
products and education. For 30 years, Stratasys products have
helped manufacturers reduce product-development time, cost, and
time-to-market, as well as reduce or eliminate tooling costs and
improve product quality. The Stratasys 3D printing ecosystem of
solutions and expertise includes: 3D printers, materials, software,
expert services, and on-demand parts production. Online
at: www.stratasys.com,
http://blog.stratasys.com and LinkedIn.
Stratasys, FDM and Fortus are registered trademarks of Stratasys
Inc. Fortus 450mc is a trademark of Stratasys, Inc. ULTEM™ is a
registered trademark of SABIC or its affiliates. All other
trademarks are the property of their respective owners, and
Stratasys assumes no responsibility with regard to the selection,
performance, or use of these non-Stratasys products.
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Stratasys Media Contacts
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Europe, Middle East, and AfricaJonathan Wake / Miguel
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15349791
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Marshall Aerospace Media Contact
Liz FullickPR ManagerLiz.Fullick@marshalladg.com+44 (0) 7825
357148+44 (0) 1223 373865
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