Growing use of additive manufacturing for
prototypes, tooling and end-use parts significantly reduces cost
and lead time compared to traditional methods
British defense, security, and aerospace giant BAE Systems (LON:
BA) has added a fourth Stratasys (NASDAQ: SSYS) F900 3D Printer to
its manufacturing site in Samlesbury, UK, in a continued effort to
reduce costs and improve production agility.
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Stratasys FDM additive manufacturing is
used across ground equipment operations for the Typhoon fighter
aircraft (Photo: Business Wire).
Along with its existing F900 line-up, the latest installation
will run around the clock as an integral part of BAE’s
transformative “Factory of the Future” initiative, a cutting-edge
facility in Lancashire which brings together the latest advances in
technology and manufacturing to work seamlessly with human
operators in a first-of-its-kind, fully connected way. Today,
Stratasys industrial-grade FDM additive manufacturing is used
across aircraft ground equipment operations for a wide range of
applications spanning space models and design verification
prototypes, manufacturing tools such as jigs and fixtures, and
final end-use parts.
Optimizing aircraft production with additive
manufacturing
According to BAE Systems, use of additive manufacturing across
these applications is making production more flexible, faster and
helping to reduce costs. Indeed, when using its F900 3D Printers to
manufacture production tools, the company says that it is
witnessing ‘significant cost and lead time reductions’ against
those of traditional manufacturing methods.
“Our Factory of the Future program is all about driving the
future of fighter aircraft production with disruptive technologies
and we’re working closely with our suppliers and wider industry to
meet the challenges the UK Government has set out to us. Stratasys
FDM additive manufacturing plays an important role in this
initiative, as it helps us meet our overall company objectives to
reduce costs and time-to-market,” says Greg Flanagan, Additive
Manufacturing Operations Lead, BAE Systems Air.
BAE Systems’ latest F900 installation will not only increase 3D
printing capacity, but also help exploit new 3D printing materials
for tooling applications. This includes carbon-fiber-filled FDM
Nylon 12CF material, which is used to create robust yet lightweight
repair and development tools for the production line.
According to Flanagan, FDM-based 3D printing technology in
particular offers an opportunity to decrease the up-front cost of
tooling for new products. This is especially so with items such as
drill tools, repair tools and other development tools that are
often needed in small numbers.
“This technology allows us to innovate many of our traditional
manufacturing processes,” he says. “We can rapidly 3D print one-off
parts for new products, replace tools more easily and
cost-effectively, and maintain production operations when hardware
is delayed. If supply chains become disrupted, having this
production power in-house also enables us to be more agile as a
business and continue to best serve the needs of our
customers.”
BAE Systems also has found great success in identifying
traditionally manufactured applications that can be enhanced, or in
some cases replaced, with high-performance 3D printing materials.
This includes utilizing durable ABS and ASA materials for a range
of aircraft ground equipment, such as cockpit floor covers for the
Typhoon fighter aircraft. “With our F900, the thermoplastic covers
can be made much faster than traditionally manufactured versions
and are a lot lighter and easier to move for the ground crew, so it
improves efficiencies within the maintenance, repair and overhaul
process. An added bonus is that they can be printed in red – the
color of all ‘remove before flight’ components,” he adds.
The latest F900 was purchased from Stratasys’ local partner
Laser Lines, through whom BAE Systems has been a Stratasys customer
since 2006.
Yann Rageul, Director Manufacturing Solutions EMEA at Stratasys,
said, “BAE System’s Factory of the Future program is a prime
example of innovative companies seeking to exploit the latest
advanced manufacturing technologies and processes to enhance
traditional production as we know it. We continue to collaborate
closely with the team at BAE to explore new solutions that further
expand the application use of additive manufacturing within
production – which will help to address and solve the company’s
current and future manufacturing challenges.”
Stratasys is a global leader in additive manufacturing or
3D printing technology and is the manufacturer of FDM®, PolyJet
Technology™, and stereolithography 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 more
than 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.
To learn more about Stratasys, visit www.stratasys.com, the
Stratasys blog, Twitter, LinkedIn, or Facebook. Stratasys reserves
the right to utilize any of the foregoing social media platforms,
including the company's websites, to share material, non-public
information pursuant to the SEC's Regulation FD. To the extent
necessary and mandated by applicable law, Stratasys will also
include such information in its public disclosure filings.
Stratasys, FDM, F900 and FDM Nylon 12CF are trademarks of
Stratasys Ltd. and/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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