Italian defense contractorLeonardo正在与英国工程公司合作SFM Technology, and large-format 3D printer manufacturerBigRep, to 3D print key components for theRoyal Navy’sAugustaWestland AW101 helicopters.
When being stored and transported on ships, the helicopters fold their blades up to make them more compact. A main rotor blade restraint cradle is used to stabilize the rotors, and prevent them from flapping in the wind. Leonardo found that their pre-existing restraint cradles weren’t living up to the required standards, and turned to SFM Technology’s AeroAdditive division to provide a solution.
通过大规模的压力测试，SFM发现3D打印零件的性能要比非印刷的零件更好，提供了轻巧且强大的产品。这款新的主转子刀片约束摇篮，尺寸为900 x 230 x 160mm，被称为第一个使用AM技术创建的同类产品。
Utilizing BigRep Pro printer and Hi-Temp CF material
In order to develop and manufacture the restraint cradles, SFM chose to leverage AM technology from BigRep. “We had a look at many aspects of 3D printing. We must look at cost, efficiency, and of course, the size, which pushed us to BigRep”, commented Gary Wilson, head of Technical Sales at SFM’s AeroAdditive division.
Due to the scale of production required for this project, SFM Technology chose to use theBigRep Pro 3D printer. This industrial 3D printer has a 1 cubic meter build volume and can produce parts at scale for all stages of the manufacturing process, making it ideal for SFM’s end-use part requirements. “We looked at the BigRep Pro as we had to look at a production 3D printer, which I believe the BigRep Pro can provide”, continued Wilson. “The machine is used as a production machine, so every rotor blade restraint cradle will be going to the end user”.
Offering automated print bed and extruder calibration, the BigRep Pro has significantly increased the speed and efficiency of SFM Technology’s production process. For instance, 30 cradles, consisting of 60 halves, have been printed since January, three-quarters more than if traditional methods had been used. “3D printing is far quicker, as we don’t have any adjustments to make, or if we do, they’re very minor and can be quickly overcome”, said Wilson.
In conjunction with the BigRep Pro printer, SFM are leveraging BigRep’s Hi-Temp CF carbon fiber reinforced material. This high-strength engineering-grade filament possesses a high heat deflection temperature of 115℃, and a 65 MPa tensile strength. Due to using this incredibly stiff and durable material, the restraint cradles are slated as possessing powerful resistance to external pressure and wear and tear. Wilson attests that multiple tests were carried out to determine the most suitable material for their budget, with Hi-Temp offering an “advantage over the other BigRep materials”.
打印过程完成后，取出支撑材料并将表面平滑。然后将灌木插入铰链中，然后添加螺旋线插入物。一旦绘制到客户的规格上，剩余的金属零件就会与摇篮内部的泡沫插入物一起添加，在安装约束摇篮时，可以保护转子刀片。
AM within the broader defense and aerospace industries
The use of 3D printing for aerospace applications is nothing new, and this is not the first time Leonardo has leveraged AM technology. Last year,Desktop MetalsubsidiaryAidrocollaborated with Leonardo to supply3D printed helicopter parts. Since receiving Leonardo’s Declaration for Qualification of Process for Additive Layer Manufacturing, Aidro has begun production of flight-ready parts for Leonardo’s rotorcraft lineup. This lineup includes high-performance civil, parapublic and military helicopters.
Leonardo has a history of utilizing AM technology for aerospace applications. In 2020, the company announced that it was leveragingRobozeARGO 500industrial 3D printers to reduce costs and lead times in the production of carbon fiber-fillednylon 6 and PEEK parts.
远离莱昂纳多（Leonardo），一月份宣布中国航空航天公司Galactic Energywas utilizing 3D printing to help manufacture the country’s largest可重复使用的火箭发动机. Additive technology fromFarsoonis leveraged to produce more than 30 3D printed parts for theWelkin 50-ton LOX/kerosene engine.
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Featured image shows an AgustaWestland AW101. Photo via Leonardo Helicopters.
