Italian defence contractorLeonardohas successfully utilized Italian 3D printer manufacturerROBOZE’sFFF (Fused Filament Fabrication) 3D printing technology to produce aerospace components.
Leonardo used ROBOZE’s ARGO line of 3D printers to manufacture a range of carbon fiber-filled nylon 6 and PEEK parts. By switching from conventional production methods to additive manufacturing (AM), the Italian defence company was able to make time and cost savings. In addition, Leonardo was able to take advantage of the increased design flexibility allowed by the process, to produce parts with increased thermal and chemical resistance.
“Techno-polymers such as Polyether Ether ketone (PEEK), combined with a high presence of chopped carbon fibers, open up some interesting horizons for development,” said Stefano Corvaglia, Intellectual Property Manager and Head of Research and Development of the Aerostructures Division. “Testing with these materials is of particular scientific and technological interest since they give some structural and chemical-physical properties of extreme technological significance to the items produced, for example thermal and chemical resistance”.
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Founded in 2014, and with headquarters based both in Bari, Italy and in Texas, ROBOZE is a developer of high-temperature FFF/FDM 3D printers and advanced thermoplastic polymers. Often referred to as “superpolymers,” parts produced using the company’s 3D printing materials such as carbon PA and carbon PEEK, are reportedly able to match the mechanical properties of those created using metals.
开发th ROBOZE进入了伙伴关系ese performance polymers with companies such asSabic和Solvay, in order to create a range of高性能丝。The EXTEM AMHH811F filament developed with SABIC for instance, is highly heat-resistant and flame-retardant, and was produced to replace metals in extreme applications.
Since the launch of the company’s一+400 3D打印机，Roboze Systems都有其特色patented beltless system。这包括Argo 500系统与其前身不同，它能够用高粘度材料（例如PEEK，ULTEM AM9085F，碳PA和PEEK）打印替换零件，并装有碳纤维。
该公司最新系列的3D打印机，雷电竞app下载the Xtreme series，在北美发射Rapid+TCT 2019。Designed to bridge the gap between the ROBOZE’s desktop and production systems, the One Xtreme and One+400 Xtreme were dubbed “desktop/production printers.” The 3D printers featured upgraded belt systems and High Viscosity Polymers (HVP) extruders, facilitating the processing of more challenging materials.
More recently, ROBOZE has collaborated with universities to develop its 3D printing technology for defence applications. In 2019 for example, the company worked withSkyBox Engineering, an aerospace research and development spin-off from theUniversity of Pisa， 生产无人机的功能零件。Additionally, the ROBOZE partnered with The特拉华大学在2020年2月，加速成品零件的3D打印和mission-critical components为了US Army。
In ROBOZE’s latest partnership with defence contractor Leonardo, the company is now attempting to develop the aerospace applications of its 3D printing technology within the defence industry.
The collaboration between ROBOZE and Leonardo
Utilizing ROBOZE ARGO 500 industrial 3D printers, Leonardo was reportedly able to remove any of the surface porosity and roughness associated with 3D printing using fused filament materials. This was somewhat due to the system’s patented beltless design, which is able to produce parts with precision levels of up to 0.01 mm. Moreover, the process is repeatable, and compatible with the highest performing polymers and composite materials, offering productivity benefits to the Italian defence contractors as well.
该测试本身旨在用基于聚合物的元素（例如碳PA和Carbon Peek）代替传统的金属模具。通过优化机器人3D打印机的打印参数，Leonardo不仅能够生产具有光滑表面的零件，而且可以保持真空，这是材料固化过程的重要组成部分。
Additionally, utilizing technopolymers within the AM process, enabled the company to use them for enhanced high-temperature applications. During testing, the high level of thermal stability provided by the polymer and carbon fiber materials did not cause significant deformations in the molds during the cross-linking vulcanization process. As a result, Leonardo found that through using these heat-resistant composites, it could reduce development costs and times compared to traditional manufacturing techniques.
The project, led by Nicola Gallo, Lead Engineer of Leonardo’s aerostructures division, was recognized during the A&T 2020 fair in Turin during February 2020, receiving the Innovation 4.0 award in the research and university category. Now, having successfully integrated 3D printing into Leonardo’s production process, the companies will examine the durability and repetition of the process within thermal cycles.
“Thermoplastic techno-polymers are made up of non-interconnected chains that are linear or have few branches. By raising the temperature, we’re able to bring them to a viscous state and therefore to shape them and, in the case of additive technology, to fabricate them in layers” added Corvaglia. “What’s more, thanks to a technology that enables us to achieve previously unattainable levels of precision in fabrication, we can improve our capacity and speed in developing prototypes.”
Heat resistance and FFF 3D printing materials
3D printing material manufacturers are increasingly developing polymers for FFF systems that display enhanced heat and chemical resistant qualities.
俄亥俄州的化学品和材料公司拉布里唑for instance, launched three new FFF thermoplastic polyurethane (TPU) materials for fused filament fabrication (FFF) 3D printing in June 2020. The thermoplastics, designed for use in FFF applications such as industrial jigs and fixtures, display长期热能性能。
Polish 3D printing filament manufacturerSpectrum Filaments, launched its newABS医疗和PETG FX120聚合物in April 2020. Both filaments are flexible, and display a high-temperature resistance.
总部位于德克萨斯州的3D打印机制造商Essentium Inc，宣布与化学和矿物质材料专家合作LEHVOSS Group发展high-performance materials2020年3月。专门针对基于生产水平的3D打印过程而创建了专门为生产级挤压工艺而创建的PEEK材料和高温尼龙（HTN）。
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Featured image shows a fighter jet developed using Leonardo’s aerospace technology. Image via Leonardo.
