Aerospace AM

Insights

Aerospace AM

How additive manufacturing and aerospace are enabling each other to evolve A Warm Welcome

This is, admittedly, one of the strangest times to be discussing the latest of the aerospace industry. We are at an interesting juncture, to say the least: one in which the commercial aviation industry is virtually at a standstill due to COVID-19 travel restrictions, but the space launch industry is entering a new and exciting phase. Put another way, in the same month that many airlines posted record losses, SpaceX became the first commercial operator to successfully launch NASA astronauts into space.

Though a strange time, it is perhaps also the ideal time to look at the ways in which the aerospace industry is using additive manufacturing to bolster its growth and evolve. As we’ve seen, many of the great achievements in recent aerospace history have been touched by AM in some way: from the advent of low- About cost rocket engines, to the development of drones and UAVs, to human jetpacks. 3dpbm is a leading AM industry media company. 3dpbm publishes 3D Printing Media Network, a global editorial website Our sixth AM Focus eBook, centered on AM in Aerospace, seeks to boost the that has grown to become a trusted and influential resource for aerospace industry at this inflection point and present additive manufacturing professional additive manufacturing. as a potential, if not obvious, way forward. AM is uniquely positioned to help the commercial aviation industry get back on its feet through more efficient Contact aircraft and flexible production and maintenance, but it is also playing a key [email protected] role in the advancement of new modes of air travel. Read on for insights into www.3dpbm.com many facets of AM in Aerospace, including a detailed market analysis by 3dpbm Co-founder and Analyst Davide Sher, enlightening interviews with ESA Cover image: © NASA and nTopology representatives and more. Other image credits on Page 60 © 2020 3D Printing Business Media Ltd. All Rights Reserved. Tess Boissonneault Editor in Chief, 3dpbm Newsletter

Table of Contents

6 Analysis A new aerospace world order

14 Interview: nTopology Ryan O’Hara, Technical Director of Aerospace and Defense, nTopology Additive Insights 22 Trends Where does commercial aviation go from here? That Matter 28 Interview: ESA Dr. Tommaso Ghidini, Head of the ESA Structures, Mechanisms & Materials Division, European Space Agency Carefully curated additive manufacturing insights and 44 Interview: Space Perspective Taber MacCallum, Co-CEO and CTO, Space Perspective the week’s top stories sent directly to your inbox

52 Mapping Ground control to major AM: 18 space companies using Breaking industry news Exclusive interviews additive manufacturing Market analyses & forecasts Case studies & applications 60 Image Credits

3dpbm.com/newsletter

Take a look AM in the New Aerospace MarketAM in ($USthe New AerospaceB) Market ($US B) Source: 3dpbm elaboration of SmarTech Analysis and Statista data

5 A new aerospace world order 8 3

AM is key in ushering in a new generation arare aerials pare ars A ars A ars of flying machines

by Davide Sher

As the aviation industry recovers from a These new means of aerial, orbital massive and unprecedented hit, the AM lessons and deep-space transportation will be learned over the last two decades are now leveraging AM for an increasingly large moving on to benefit other segments of the number of parts. Initially because AM will aerospace business, driven by advancements support the smaller batch production in space as well as in VTOLs, drones, helicopters requirements with tool-less manufacturing and a number of other flying defense products. and a streamlined supply chain. Eventually, as these industries continue to grow, so Additive manufacturing is a key enabling will AM’s productivity rates, so that even technology in the ushering in of a new mass production will be enabled through era for the aerospace industry, one where the digital additive workflow. Considering personal air transportation is no longer that in many cases these will be personal just for the extraordinarily wealthy, and transportation devices, personalization will space is no longer an impossible dream for also be a major driver to adopt AM for its 99.9999996% (est.) of the human population. mass customization potential.

AM Focus 2020 Aerospace / Analysis 7 Space Additive Manufacturing Market ($US B)

Space Additive Manufacturing Market ($US B) Source: 3dpbm elaboration of SmarTech Analysis and Statista data At 3dpbm, we have built upon some for an increasing number of operations and of the most recent market research for services. At the same time, the benefits of AM each of these segments, and combined it in the production of thrusters are so evident 5.25 with our deep understanding of the AM that almost all companies now use these market to present a forecast of the revenue processes, even those, such as Astra, who opportunities that this new aerospace tend to avoid using 3D printing in favor of 3.5 world order may bring to AM hardware simpler parts. Other companies, like Rocket and AM materials manufacturers, as well Lab and Relativity, try to use 3D printing as

as AM Service providers and AM parts much as possible, likely leading to a number manufacturers. of yet undiscovered benefits. 1.75 We are thus able to present a scenario This is the space industry as we know it today where this new aerospace segment will on Earth. However, the not too distant future grow into a $17 billion market by 2030, up will see 3D printing increasingly used to from about $3 billion today. This figure travel through and stay in outer space. Like includes all AM hardware and AM materials, SpaceX’s Crew Dragon, a number of other as well as AM parts produced in the three vehicles such as Boeing’s Starliner and NASA’s

arare aerials ars primary segments we have identified: Orion—not to mention SpaceX’s own Starship, Space, Personal Air Transportation (PAT) now a top priority—will soon be taking and Unmanned Aerial Vehicles (UAV). Which humans into orbit, to the Moon and to Mars. Additively Manufactured Space Parts ($US B) types of AM parts will be produced for each All of these have already shown their use of of these segments and how much they will 3D printing—both polymer and metal—for Additively Manufactured Space Parts ($US B) 1.8 be worth is going to be discussed in the a number of structural parts. However, the Source: 3dpbm elaboration of SmarTech Analysis and Statista data following sections. most significant benefits of AM will come from the ability to produce parts directly in orbit or on the Moon or Mars, in what ESA

1.35 AM applications for the commercial refers to as “Out of Earth Manufacturing”. space industry This implies a heavy use of AM for on-location production of spare parts, space outposts SpaceX’s successes have definitively ushered and even planetary bases. None of these

0.9 in the era of commercial space applications will be possible without AM and with and exploration. However, SpaceX is not the the first Lunar space station expected to only commercial space company whose become operational by 2024, the timeline success is in some way connected to 3D for implementation is tight. These and other

0.45 printing. As confirmed by Dr. Ghidini in the elements of our analysis are reflected in the extensive interview published in this eBook, forecasts below. key parts are already in production for space, including a large number of satellite Due to the very high value of parts for brackets and launcher (rocket) components, space vehicles and the extreme benefits of such as engine parts. This demand is only printing off-Earth, the revenues (or revenue going to grow exponentially as satellites equivalent) of printed parts eclipses that of aellies ancers pacecra o ar are produced into constellation networks hardware and materials.

AM Focus 2020 Aerospace / Analysis 9 PAT Additive Manufacturing Market ($US B)

Personal Air Transportation AM Market ($US B) Source: 3dpbm elaboration of SmarTech Analysis and Statista data Off-Earth manufacturing represents a period, by reducing the cost of personal air negligible part of the Space AM parts market transportation and making it available to a today but it will grow significantly in the larger number of people. This segment also 7.5 second half of this decade. Parts for launchers includes another segment that was relegated and satellites remain the biggest segments as to the realm of science fiction until a short we move into mass manufacturing. time ago: jet suits. Gravity Industries has demonstrated that jet suits are a reality and 5 that they will be almost entirely 3D printed. Personal air transportation (PAT) evolved The value of parts for personal air transportation is not as high as in space, and 2.5 In this analysis, the segment for personal will require high productivity systems leading air transportation also includes what is to greater revenues associated with both commonly referred to as civil aviation, or the hardware and materials in this segment. market for private planes. Also included is the commercial helicopter market. These are Rapid expected growth in the VTOL segment, both “traditional aviation” segments that are combined with significant adoption of expected to continue to grow significantly additive manufacturing processes for the arare aerials ars as COVID-19 limitations hinder general production of these new generation devices, aviation reducing demand for large aircraft. will drive this segment to become a larger Total Additive Manufacturing Revenues ($USB) in Solar Power Generation Both these markets have been significant opportunity for AM-related revenues than adopters of additive manufacturing. traditional aviation segments such as private Private planes have been using AM for the planes and commercial helicopters. Personal Air Transportation AM Parts ($US B) Source: 3dpbm elaboration of SmarTech Analysis and Statista data production of a number of custom cabin parts, with relevant ongoing projects at GE to 3D print several parts of the Turboprop A UAV for everything 2.25 engine (including air-air heat exchangers) that will powder the Cessna Denali. Use of Like the commercial space market, the AM for helicopters has mainly centered on commercial flying drone market is very military models, however, the experience much reality already. The total drone market, 1.5 built by Airbus Helicopters, Russian including the consumer, military and Helicopters and Leonardo is expected to commercial sectors, is estimated to reach also be applied in commercial and private $100 billion by 2020. Though 70% of this figure helicopter manufacturing. is linked to military activities, the commercial 0.75 business is the fastest growth opportunity, The most significant new trend in PAT is projected to reach $13 billion by 2020. the emergence of VTOLs (vertical take-off and landing) vehicles, in particular those UAVs are flying drones, which is essentially powered electrically (eVTOLs). Projects such robotic air transportation (as opposed to as the Electrafly eVTOL indicate that this personal air transportation), but that doesn’t segment is set to become a major driver make for a very nice acronym. Because for AM adoption by the end of the forecast UAVs are all very similar in structure, they riae es elicopers s

AM Focus 2020 Aerospace / Analysis 11 UAV Additive Manufacturing Market ($US B)

UAV Additive Manufacturing Market ($US B)

Source: 3dpbm elaboration of SmarTech Analysis and Statista data can be differentiated primarily by the type Because they are transversal, the consumer of service they provide. Drones can vary in and 3D mapping segments are the ones

1.5 shape and size, but the main core elements that are expected to drive the most demand (battery, microcontroller, motor, sensors) are for drone units and parts. Consumer UAVs essentially the same. are to be considered a separate segment as they use different drone systems that 1 While personal drones dominate unit sales at have a lower price per unit than all other 94% of the market, they only comprise 40% of commercial UAV segments. the market’s revenue share. Commercial drones only represent 6% of the market, but their 3D mapping includes surveying sites 0.5 price tags of around $100,000 are projected and taking photos to create maps. Other to represent 60% of the industry’s revenue. In immediate uses for UAVs include inspections terms of AM adoption, the commercial drone of difficult-to-reach areas at certain altitudes industry is likely to follow a similar evolutionary or in contaminated environments, as well trend as the automotive industry, with a greater as aerial analysis of infrastructure, such focus on prototyping and, eventually, on the as pipelines, solar panels, electric grids use of production-grade polymer technologies. and offshore platforms. Other uses are

arare aerials ars Polymer extrusion and polymer powder bed longer term: these include delivery (both fusion are expected to be the most widely commercial and delivery of medical supplies UAV AM Parts Revenues by UAV Use Segment ($US B) adopted technologies in the drone industry in remote areas) and data transmission. because they are currently the only ones More futuristic uses will see drones used in UAV AM Parts Revenues by UAV Use Segment ($US B) fit for end-part production as well as rapid emergency and fire rescue, with the ultimate Source: 3dpbm elaboration of SmarTech Analysis and Statista data prototyping activities. goal being mass production. Like cubesat constellations, the future will see more and 0.3 While the very well-funded commercial UAV more small size UAVs function together manufacturers remain quiet about their through swarm intelligence to perform use of AM, a large library of application case complex tasks. Here again, high productivity studies has emerged recently and includes polymer AM processes will prove ideal for

0.2 the use of metal binder jetting additive production of a large number of complex manufacturing for engine parts and both lightweight drone parts. ◆ polymer powder bed fusion and filament extrusion for complex structural parts.

0.1 Aerospace AM Study Since drone hardware has become more affordable to produce and purchase, At 3dpbm Research we’re conducting a new comprehensive study on the aerospace AM services that operate and manage drones market for 2020–2030, taking into account the for companies will generate most of the impact COVID-19 has had on this segment. value and thus drive demand for parts. We If you’re an AM hardware, software, materials have identified and quantified the overall or service provider for aerospace applications, AM market for commercial UAVs as well as please contact us to participate in this study. erency eliery Ariclre ornalis/ilain primary commercial UAV adoption areas in [email protected] nspecions appin onser the forecasts below.

AM Focus 2020 Aerospace / Analysis 13 DfAM takes aerospace to new heights

3D printed Fuel Cooled Oil Cooler (FCOC) redesigned and optimized for AM using nTop Platform and ANSYS CFX.1 A discussion with Ryan O’Hara, Technical Director of Aerospace and Defense, nTopology

When you talk about additive manufacturing power of engineering design for aerospace in the aerospace industry, it is impossible not applications, we spoke to Ryan O’Hara, the to discuss design. Design is one of - if not - the Technical Director of Aerospace and Defense most important driving factors behind AM’s at nTopology Inc. benefits in the development of aerospace parts. Design is what enables innovation in A bit of background lightweighting and gains in performance efficiency. In a word, design is critical. nTopology will be a familiar name to many in the industry, as it is one of the leading Considering this, we felt it important to engineering software companies specializing not only consider AM in aerospace from in design for additive manufacturing (DfAM). the hardware and aerospace sides, but In 2019, the New York-based company also from the perspective of engineering launched nTop Platform, a complete design software - we should note here engineering workflow that is offered that here our definition of design also through an annual subscription mode. encompasses simulation and manufacturing “Modern design engineering ecosystems are analysis. To shed some light onto the continually trying to pull more information

In collaboration with AM Focus 2020 Aerospace / Interview 15 “nTop Platform embraces the most useful aspects of CAD, CAE, CAM and topology optimization.”

that allows for lightning-fast iterations and and governance for reliable, consistent unlimited geometric complexity; field driven and validated results without the need for design that uses geometry, simulation and human involvement at every step.” manufacturing fields to drive geometric design to optimize the part; and the ability to Rising to the nTop of aerospace create workflows that can be reused, shared, remixed and automated. Today, more than 30% of nTopology’s clients are from the aerospace industry, and the “nTop Platform has provided a combination company’s nTop Platform is in use at some of of workflows that directly facilitate DfAM the world’s largest aerospace firms to assist nTopology’s nTop Platform enables users to generate AM-optimized geometries through the AM Toolkit.2 process steps. These include workflows for in the development of new and innovative lightweighting, architected materials and parts. The platform’s appeal comes in large direct export of slice data to certain build part from its design capabilities, as well as its processes. nTop Platform also allows users efficient workflow. forward in the process in an effort to enable application on top of the platform, providing to deploy their own workflows within a engineers to make use of downstream a top-level design engineering environment company. In one instance, an experienced “In today’s design environment, engineers knowledge early in the design process,” that captures the work, skill and engineering AM manufacturing engineer was able to are tasked with having to produce higher O’Hara explained. “This is especially know-how of each design team member.” leverage nTop Platform to configure a performing parts with a given design important in advanced manufacturing workflow that could be used as a time and volume,” O’Hara explains. “They are asked to applications, where the downstream From a design perspective, nTop Platform cost estimator and shared with a team do this on shorter and shorter design cycles, manufacturing process can have a enables users to generate AM-optimized of design engineers. As such, the design all while making their components lighter.” significant impact on design decisions from geometries through its AM Toolkit, which engineers could see in near real-time the the onset of the design process. combines topology optimization algorithms effects of their design decisions on the Looking specifically at the benefits of nTop and field-driven design technology. In downstream AM processes.” Platform and additive manufacturing in “nTop Platform provides a common practice, this means that parts can be aerospace, O’Hara identifies three key areas: foundation so that engineers across a designed to only have material where it is nTop Platform is easily integrated with the maximization of part performance, the number of disciplines including design, needed, while still meeting performance existing CAD, CAE and CAM platforms, to consolidation of design and the production simulation and manufacturing can capture specifications and manufacturing limitations facilitate seamless workflows for its clients. of lighter parts. their own piece of the process, send it (i.e. overhang angles, wall thicknesses, etc). “nTop Platform embraces the most useful upstream (or downstream) and leverage aspects of CAD, CAE, CAM and topology “nTop Platform and AM fundamentally that of others at any point. Additionally, O’Hara states: “The three key drivers that set optimization, and it integrates with all enable three specific areas for the aerospace various pieces of workflow knowledge nTopology apart from other software vendors modern engineering systems,” O’Hara industry,” he elaborates. “First, the ability to can be configured into a larger process or are: unbreakable modeling technology says. “It also adds a new layer of control maximize part performance in a way that

AM Focus 2020 Aerospace / Interview 17 Left: FCOC color map of HTC values with oil velocity streamlines, right: fuel velocity streamlines with oil HTC.3

environment without geometry bottlenecks,” O’Hara says. “nTop Platform allows engineers to fully utilize their computers to understand and solve hard problems.

“Anytime the barriers to design and subsequent manufacturing can be removed, there will always be a benefit to the designer, manufacturer and, ultimately, the end-user. nTopology’s fundamental goal is to allow engineers to be able to generate geometry without limitations. When these parts can be quickly and easily realized in the physical space, huge opportunities become available for all those individuals involved in the design process.” was not previously possible with traditional Where additive and DfAM make the design and manufacturing methods by biggest impact allowing for the generation and fabrication Over 30% of nTopology’s current clients are from the aerospace industry.4 of complex shapes that have direct effects on In the aerospace sector, there are a vast the fundamental function of the component. number of parts that can be designed, redesigned and optimized using AM, from Second, consolidation of design: by engine components to interior cabin structures. decreasing the number of sub-components According to O’Hara, however, one of the part not possible with traditional design and The design was inspired by a project led and making the parts multi-functional groups that will benefit the most from additive manufacturing processes.” by America Makes aimed at leveraging AM it allows for fewer components, reduced manufacturing is heat exchangers. to redesign a legacy shell and tube HEX to assembly time and more reliable systems. In one example, nTopology’s software was determine whether advanced design and Third, aerospace components can “Far and away the biggest limitation to air used in combination with ANSYS CFX to manufacturing could increase performance. be improved by using geometry that and space components is the mitigation redesign a Fuel Cooled Oil Cooler (FCOC). uses material more efficiently through and handling of heat,” he explains. “Heat The report, which can be read in full here, In this case, nTop Platform enabled engineers optimization algorithms, periodic structures from a turbine engine, electronic device or details the process from initial redesign in to define a volume for the part which could and field-driven design methods to produce working fluid often needs to be transported CAD, to process steps in nTop Platform and act as a basis for the modified FCOC design, lighter parts.” in a way that ensures the critical engineering to final Computational Fluid Dynamics (CFD) maximizing surface area while minimizing process that the heat comes from can and analysis steps in ANSYS CFX. mass in its interior walls. The surface area Compared to other engineering software be maintained. Heat exchangers are of the part was maximized using a Triply solutions, nTop Platform stands out in a fundamental to these processes and require 300% increase in heat transfer Periodic Minimal Surface (TPMS), also known critical way. That is, while most modeling complex internal geometries to be effective. as gyroid structure. By implementing this environments are built to document nTopology and AM are able to deliver huge The part in question is a high-performance structure in the heat exchanger design, the an engineering solution, nTop Platform gains in performance by increasing surface heat exchanger (HEX) used in the aerospace team achieved a 146% increase in surface area actually creates one. “nTopology integrates and decreasing wall thickness to enable the industry, which exchanges heat between compared to traditional tube and shell HEX of mathematics and simulation to create a single exchange of heat in ways that are simply the engine oil and the fuel of an aircraft. the same size.

AM Focus 2020 Aerospace / Interview 19 Software programs like nTop Platform are key to unlocking the benefits of additive manufacturing in RECENT EDITIONS aerospace and beyond.5

aluminum alloys for AM. Overall, the increased surface area and minimized wall thickness of the FCOC resulted in a 300% increase in heat transfer compared to the legacy component. MAY AM Sustainability

All this was achieved using nTop Platform In the additive manufacturing industry, the with the support of ANSYS CFX capabilities, question of sustainability is an interesting which provided computational fluid and multifaceted one. This eBook opens up dynamics simulation to evaluate the a focused dialogue within the AM sector performance of the redesigned FCOC. The by presenting analyses and insights from software company concludes: “nTop Platform some of those seeking to understand the allows the user to create complex geometries ecological implications of AM and those that (TPMS structures, fluid volumes, smooth are setting an example. lattice-solid transitions), while maintaining complex control over the geometric model, and then easily allows the user to export the geometry outside of nTop Platform for validation and verification.” Read now

The key is design

It is becoming increasingly apparent that additive manufacturing is unlocking new application opportunities in the aerospace “When coupled with advanced industry, through the production of more manufacturing methods, these TPMS efficient and often higher performing parts. structures enable parts with both high As we’ve seen, additive manufacturing APRIL Advanced Materials strength and heat dissipative requirements to systems are not unlocking these capabilities be designed in a manner that was previously on their own: sophisticated software Bringing you an in-depth analysis of the advanced materials Read now impossible to achieve,” says O’Hara. programs such as nTop Platform are really landscape, as well as a glimpse into the work of some of the at the core of these benefits and allow AM’s leading companies in ceramics and advanced composites. The wall thickness of the component was potential to be fully exploited. minimized thanks in large part to the use of a nano-functionalized high-strength 7000 nTopology is one of the companies pushing series aluminum alloy (7A77), which was AM technologies and applications ahead developed specifically for AM. The superior from the software side, with an integrated strength of the metal enabled thinner platform that removes geometric barriers MARCH Consumer AM interior walls in the part without sacrificing to advanced design and enables the strength or performance. In fact, the gyroid maximization of part performance, the Exploring the rapidly growing market for consumer AM Read now structure has walls about half the thickness consolidation of design and the production products, with an exclusive interview, case studies and a of those made from traditional casting-grade of lighter parts. ◆ comprehensive overview of leaders in the sector. Where does commercial aviation go from here? COVID-19 has had a dramatic impact on most industries, but the commercial aviation market has been hit particularly hard.6 Let’s talk about the elephant in the room

In previous market studies we have based Air traffic dropped by as much as 90% - not our forecasts for the potential of additive just for people but for products as well, manufacturing in the aerospace segment dramatically affecting supply chains all over on the assumption—shared by most— the world. that the commercial aviation segment would continue to experience significant The impact of this drop in aircraft growth. Even the recent nationalistic manufacturing has not been fully seen or and anti-globalization efforts by some understood yet. Boeing did immediately world leaders seemed unable to curb the slash nearly 13,000 jobs (in the U.S. job cuts increasingly free transportation of people are quick) and Airbus also initiated talks and merchandise across the globe. Then with unions on massive cuts (in Europe cuts came COVID-19, which showed us that a take longer). The company furloughed 6,000 virus could be way more powerful than the employees and Airbus’ CEO said it is only the most powerful humans in creating social start. Rolls Royce, a major jet engine supplier, and physical distancing. The commercial is considering over 8,000 job cuts. The aviation segment—the primary beneficiary situation is dramatic, there is no question of globalization—collapsed overnight. about it, and it is going to get much worse

AM Focus 2020 Aerospace / Trends 23 before it gets better (though we do expect applied to the energy and automotive “Additive manufacturing adoption in that it will eventually get better). But the segments. It’s fair to say that many AM big question on our minds, as AM industry hardware companies would have gone under the commercial aviation segment was media, is “how is this going to affect additive long ago if it weren’t for investments made manufacturing?”. by commercial aviation stakeholders. not driven by an abstract desire to

The aerospace industry, and the commercial Their impact is not just direct (meaning they advance the technology” aviation segment in particular, have been buy machines), but also indirect. By making the main drivers of AM for the better part of it clear that AM is going to be the way to go the last two decades. Aircraft manufacturers for the future, aircraft manufacturers and such as Airbus and Boeing, along with tier 1 suppliers drove airline CROs and tier engine manufacturers like GE Aviation, 2/tier 3 suppliers to also invest in adopting seen as a way to achieve three goals: hundreds of billions in yearly revenues, Rolls Royce and Honeywell, have been the these technologies. automating and streamlining production, aircraft manufacturing is one of the absolute leaders in the industrialization of digitizing warehouses and spare parts on backbones of the global manufacturing AM processes, helping to evolve them from demand, and making more economically industry. Central governments in the U.S., prototyping and tooling activities to full- Why AM? and environmentally sustainable aircraft by China and Europe are likely to provide scale, end-use part production. reducing overall weight and thus reducing incentives and financial support, taking AM adoption in the commercial aviation fuel consumption and emissions. advantage of the situation to demand The lessons learned in the commercial segment was not driven only by an abstract technological innovation and more aviation segment are now being increasingly desire to advance the technology. It was These well-identified benefits of AM have sustainable practices as a condition to not magically disappeared with COVID-19. obtain the funds. This also may play into If anything, they now hold even greater greater adoption of AM technologies. importance. However, fully implementing them will still require significant investments. Times of economic turmoil and

crises are not always the ideal landscape to AM can enable aircraft manufacturers to make more drive investments in new technologies and economical and sustainable parts.8 processes. But they should be.

Whether these investments will in fact materialize will depend on many factors. One—sad as it may be—is the fact that cutting so many humans from the workforce will drive more automation. Additive manufacturing may benefit from more automated workflows. Then again, all industries should be mindful of the fact that if people don’t work, they certainly don’t travel or buy things that need to be transported.

Another factor will depend on institutional investments to overcome the crisis. With

ULTEM 9085 aircraft interior parts printed by Stratasys which meet stringent FAA and EASA certification requirements.7 AM Focus 2020 Aerospace / Trends 25 UPCOMING EDITIONS

A scarier prospect is that current geopolitical Survival of the fittest tensions, exacerbated by the pandemic and ensuing global economic crisis, will There are many more reasons why AM will continue to escalate, driving governments eventually benefit from the current situation to invest even more in defense, which is in the commercial aviation segment— JULY AM Automation another major adopting segment (closely including new businesses that will open up in interconnected) for AM. For many companies what we have defined as the “new aerospace Automation is gaining in importance active in commercial aviation, defense world order” in the analysis piece in this as we shift towards Industry 4.0. This is another major source of revenue that eBook. The idea of spare parts on demand eBook will dive into how AM and can help get through the challenging and digital warehouses, initially implemented automation are intertwined and consider times ahead, with the hope that growing to streamline CRO operations, can and will how automation represents the most tensions don’t lead to larger conflicts. The be expanded to include the large number important path for AM to achieve announcement by Lockheed Martin that the of cabin modifications that will need to be production readiness and scalability. company would hire 8,300 new positions implemented in order to meet COVID-19 right in the middle of the pandemic may safety requirements. In many cases, it will be an indication of this trend. The U.S. be more convenient to internally 3D print Analysis Department of Defense (DoD) is one of the an adapter rather than purchase an entire Interviews largest adopters (and a major driver for injection molded replacement kit through the Case Studies innovation) of AM technologies, as are major standard supply chains. Mapping arms manufacturers in Italy and France, as well in China, India and Russia. For all these reasons, the long term prospects for AM in commercial aviation are rosy. However, the short term impact of the pandemic on AM investments by commercial aviation stakeholders is likely going to be Flight bag support device 3D printed by Eastern Airlines dramatic. Perhaps even more so for metal Technic AM lab in ULTEM 9085 on a Fortus 450mc.9 AM (used to make engines and structural AUGUST AM Service Bureaus SEPTEMBER Dental AM parts) than for polymers (which are used for cabin and replacement parts). The pandemic AM service providers are the most relevant The dental segment has been a critical is also accelerating processes that were segment for short term rapid growth. We driver of AM adoption. Today, dental labs already underway. explore the ideal way to benefit from AM across the world are using AM to improve without a high initial CapEx. patient care and streamline production. Even before the pandemic, it was not clear if all AM companies would be able to survive for the time it would take for the transition into digital additive mass production to be completed. By further reducing available investment capital, while making Enquire about sponsorship opportunities this transition even more urgent, a more Get in touch dramatic selection is likely to occur. Some AM Have an interesting story to share and want to reach companies will not survive it. But the ones a broad network of professionals? Let’s talk. that do are going to reap the benefits.◆ AM at ESA, the alpha and omega

Dr. Tommaso Ghidini, Head of the ESA Structures, Mechanisms & Materials Division.10 AM has allowed us to get closer than ever to space. Dr. Tommaso Ghidini, Head of the ESA Structures, Mechanisms & Materials Division, explains how. Space is the initial frontier for additive major civil and military programs of the manufacturing. It is where AM makes the European aeronautical industry, including most sense and where it has made the the A380, A350 and A400M aircraft. most sense from the very start. As Head of the Structures, Mechanisms and Materials This experience was instrumental in Division at the European Space Agency, running a very large number of additive Dr. Tommaso Ghidini is in charge of manufacturing programs and tests over identifying and maturing manufacturing the past decade. As Dr. Ghidini explains technologies for use in space exploration. in this exclusive and quite extensive interview, the moment ESA scientists and His division provides engineering support engineers understood what they could do to all missions that are currently flying, with AM, a universe of possibilities opened from telecommunication satellites, to up. AM is one of the enabling technologies scientific missions in deep space, to that will make human space travel first exploration missions on other planets, to more accessible and then more affordable. human space flight, to rockets bringing From Earth up to orbit, from orbit into payloads and astronauts into space. Before deep space, and then onto the surface of ESA, Dr. Ghidini worked for Airbus on all other planets.

AM Focus 2020 Aerospace / Interview 29 “To really benefit from AM, especially The Structures, Mechanisms and Materials in qualifying all the materials, processes, Division is the largest division within ESA, systems, subsystems and electronic in space applications, you need to with more than a hundred people working equipment of any structure. “Should within it. AM receives a significant portion something go wrong - because sometimes design for AM” of the funding with all 22 member states things do go wrong - we act as a completely that support ESA clearly understanding independent and impartial authority to its importance. The division’s work is perform a tailored failure investigation, kind expansive, and starts in the mission design of like the ‘CSI of space’,” he explains. phase. As the required physical hardware is required - but also guaranteeing that the laboratory for investigation. We understood for a particular mission is defined, the Once the spacecraft has been built and all spacecraft will disintegrate on the descent the problem and fixed it. That’s it. Nothing to division provides support, engineering possible failures have been resolved, comes back to Earth.” do with additive. What it did have to do with services and sophisticated numerical and the moment of truth: full-scale testing. “In additive is that that particular valve was, from experimental analysis on a large number of the past, our responsibilities ended with In addition to day-to-day activities, Dr. Ghidini’s a manufacturing point of view, an ideal case hardware interactions and on all possible the launch phases and operations. We have division works to identify the technologies that study to try out this new technology.” systems and subsystems. now added ‘design for demise’ capabilities, can enable future missions. “We screen the which means we need to ensure not only market to identify the technologies and then At the time, plastic AM was being used for “Once the design is ‘blessed’, we start on that a spacecraft can carry out the mission we mature them for space applications.” That’s prototypes but metal AM was still in its early manufacturing it,” Dr. Ghidini tells 3dpbm. - launching, reaching space or a planet and how AM came into the picture. If you like days. ESA teamed up with Airbus and decided This means supporting manufacturers operating for whatever number of years it additive and you are fascinated by space, strap to use this as a case study. “We were shocked in, and get comfortable: it’s going to be a ride by the results. Going from subtractive to out of this world. additive, we reduced material waste from 75% to 5%. Using so much less material, it made economic sense to move from stainless steel From case studies to to titanium, which is more expensive but standardization also has a superior weight-to-strength ratio.” The part’s weight was reduced by 50% and How AM began its journey at ESA is a manufacturing time by several hours. Instead fascinating story, one that many AM of welding two pieces together, which would adopters can relate to. “It dates back to 2006 require additional inspections, it was built in and it started with a failure,” Dr. Ghidini one go. “So, in a way, we won. But,” Dr. Ghidini tells us. “We had a major anomaly in the concedes, ”we did not.” International Space Station (ISS). A water pump’s on/off valve in the Columbus module This is the story of the second failure: a failed. That valve is extremely important common mistake when approaching 3D because it regulates temperature. The ISS printing. “We just replicated an old design,” goes from +180°C when it’s exposed to the Dr. Ghidini says. “We reproduced the valve as Sun, to -180°C when it is in the shadow of the it was. To really benefit from AM, especially in Earth: a 360°C thermal gradient. We need space applications, you need to design for AM.” to keep the temperature inside the station at 22°C to be comfortable for the astronauts Dr. Ghidini continues: “As we learned our on board. So, we had the Space Shuttle lesson, we realized that, for the very first time, bring the valve back to Earth and to our we had access to a manufacturing technology

ESA, ArianeGroup and DLR German Aerospace Center have built and hot-fire tested a fully additively manufactured thrust chamber.11 AM Focus 2020 Aerospace / Interview 31 that enabled us to move from design for are flying to the Sun and to the outer manufacturing to design for performance: planets. We are landing on other planets. growing parts like Mother Nature does. We We have missions that need to operate realized we could distribute the material to in incredibly aggressive environments for where the loads are. And we understood that many years. And we have a very limited we could dramatically reduce mass, which production scale. Furthermore, there is a key priority for any part that needs to be are few manufacturing processes that lifted into orbit.” can achieve the performances we want, combined with very high reliability. Once a Every kilogram of mass launched into space part is in space, it’s gone. And it may have to can cost between tens of thousands up to a function continuously for decades without hundred thousand dollars, depending on the any maintenance or repair.” distance from Earth. In addition, a launcher has limited space available. So, the smaller the Additive provided a possible solution to all parts are, the better. However, making small of these challenges. First, because it works parts also means more intricate geometries well on a small series of complex parts. It and a harder time procuring materials. also works with a large variety of materials: from metals and polymers, to composites “The material supply chain is very and ceramics, to food, cells (with Twin robotic arms work together as part of a project to construct what will be the largest, most complex object ever 3D challenging for us because we require bioprinting), concretes and geopolymers. printed in titanium: a test version of the 3m diameter ‘optic bench’ at the heart of ESA’s Athena X-ray observatory.13 extremely high performances and very You can now use AM on structures ranging small quantities,” Dr. Ghidini explains. “We in size from micrometers to meters. AM has enabled weight savings up to 90% and lead time reductions of several weeks, with a This organically-styled bracket, designed for the interior compressed manufacturing chain on very Roadmap to space This roadmap details timelines and of an Ariane launcher, was 3D printed in space-worthy titanium alloy for an R&D project.12 complex assemblies. By removing bolts requirements needed for safe use of and welds, it is now possible to produce It took some time to ensure that AM was additive manufacturing [download PDF]. structures that were not possible using reliable for space. Having a rocket blow up It also addresses the major issues to traditional manufacturing, even embedding or a satellite lost because of an additive be resolved, such as dimensional and new capabilities, such as thermal functions, manufacturing failure would have killed the design challenges. “We noted that we into a structure. technology in the early days. Today additive had no design guidelines and no end- parts are flying, as ESA has successfully to-end tools to go from CAD to CAE to “Consider, for example, that a thruster today moved from demonstrators to flight topology optimization and then on to is made of almost 200 parts that need to be missions. But the path was not so clear cut. manufacturing, taking into consideration assembled,” Dr. Ghidini says. “Now you can “In the beginning, we saw a frightening complexity as well as residual stresses have a thruster done in one piece.” But not mushrooming effect: everyone proposed and build strategies.” Another challenge everything that shines is gold. “As we saw themselves as AM experts. We realized was material-related: powder quality the tremendous benefits, we also started to we needed to have a centralized strategy control, supply chain and reproducible identify the possible issues,” he adds. “One is in Europe, so we created the European quality of the powder. “We needed to that wanting to use additive for everything is Roadmap for Additive Manufacturing for guarantee a harmonized standard quality counter-productive. So, a big part of our job Space Applications. All European partners from our manufacturing partners,” is to decide where it makes sense to use it.” contributed, and ESA chaired it.” Dr. Ghidini says. “Then we moved to

AM Focus 2020 Aerospace / Interview 33 A titanium 3D printed prototype of a deployment mechanism for satellite solar panels, by Thales Alenia Space.14

company in the space industry and want to From Earth to orbit implement AM, you can find a center that has all the machines, all the technologies, The first applications to consider are all the materials to help you mature your structural applications. This is where Dr. process or application for space.” Ghidini’s division works to reduce the buy- to-fly ratio dramatically while increasing Dr. Ghidini’s division also created a map mechanical performances. “We started of the AM powder producers in Europe. with secondary structures, which do not “We checked the quality they were able cause catastrophic loss if they fail, such to achieve in terms of reproducibility, size, as brackets,” he tells 3dpbm. “Now we are shape and composition of the powder. getting more confident and are addressing Then, on the same machine, with the primary structures as well.” same parameters, we produced the same samples to see how the different powders In order to further develop lattice structures behave for each different material. We for weight optimization, the first step ESA came up with this set of procurement took was to ask Airbus to review an entire specifications for space-grade additive rocket series, Ariane, and identify where to manufacturing powder.” Another tool made apply AM. The results pointed to 20 to 25 available is a fractography atlas of additive brackets in each launcher, for a total of over manufacturing parts based on known 30% in cost savings. Then the agency looked modes of rupture, such as static overload, at space propulsion. This is where AM can fatigue, corrosion and stress corrosion bring the most benefits, by dramatically cracking. “For this, we systematically took reducing part count (from almost 200 to just pictures of the fracture surface so as to one in case of thrusters) and by producing the manufacturing challenges: process Any industry can adopt these standards. guide engineers as we open a completely monitoring, processing strategy, post- Requirements can be downgraded for less new chapter of metallurgy.” processing such as surface treatment and extreme conditions, but the document surface engineering.” provides a clear guide on how to use and test Taking advantage of additive manufacturing, the Solar AM parts. “It can be useful to have a standard Taking AM to new worlds Orbiter Sun Sensor Bracket was re-designed using a Making it work procedure,” he adds. “We provide an ideal lattice geometry.15 approach that can be tailored to specific needs ESA was systematic in defining the possible Another key issue is the qualification and and will help further the AM market uptake.” applications for AM in space, dividing verification strategy, including mechanical them into three domains. The first is characterization, numerical predictions, In order to implement the roadmap through additive manufacturing on Earth. That fatigue analysis and nondestructive a centralized, consolidated and strategic is, the production of optimized parts for investigations (NDI). “Once we defined our approach, ESA created two ESA Additive spacecraft and rockets here on Earth. The strategy to qualify parts, we moved on to Manufacturing Benchmarking Centers: one second is additive manufacturing in orbit - standardization,” Dr. Ghidini explains. “We is at the MTC in Coventry, UK. The other one on the ISS, for example. Finally, is additive leveraged ECSS, the European Consortium is in Dresden, Germany, at the Fraunhofer manufacturing on other worlds (such as for Space Standardization. This AM standard Institute. “We address all the fundamental the Moon or Mars). Each has very different for space is something that my division has challenges that need to be solved for a requirements but sometimes there are led and we will publish this year.” specific use,” Dr. Ghidini states. “If you are a opportunities for cross-fertilization.

AM Focus 2020 Aerospace / Interview 35 ESA successfully tested 3D printing with simulated Lunar and Martian regolith.

This 1.5 tonne 3D printed structure is proof of concept for the building block of a future Moon base.16 very intricate structures, such as injector parts for the mirror structure of the Athena heads with channels that no traditional X-ray observatory, a super telescope for manufacturing process can produce, or space investigation due to launch in 2031. exhaust cones with embedded radiators for He says: “We tested a hybrid rapid plasma optimal heat dissipation. deposition (RPD) technology, a type of wire arc additive manufacturing (WAAM) process, In 2015, ESA and Airbus produced the first 3D and combined it with a subtractive system to printed platinum combustion chamber ever. produce meter-long parts.” Platinum is an ideal material for propulsion, however, it is impractical to use in traditional AM parts are now baselined for a number manufacturing, because of material waste of ESA missions. The first satellites that (and relative cost), and because it is very integrate additive parts include Sentinel-4, difficult to forge and treat. Another key the Quantum telecommunications satellite, space application for AM is radio-frequency and Electra, a geostationary satellite using (RF) equipment. Advantages include a mass only electric propulsion. There soon will reduction (up to 50%) and eliminating the be parts flying on the JUICE (JUpiter ICy need for subassemblies. “The key aspect moons Explorer) mission, launching to to consider is geometry,” Dr. Ghidini adds. the Jovian system in 2022 (and arriving in “Antennas used to transmit data should not 2029). The Vega -E, Ariane6 and Ariane5 A selection of 3D printed ceramic parts made from a simulated lunar regolith material.18 have sharp edges. With AM we can build rockets also integrate AM parts. The very the antenna in one go and with the ideal first part, installed on an Ariane5 in 2016, geometry for optimal RF performance.” was a cardan cross: this is a structural part in the exhaust lines of the Vulcain 2 cryogenic Moving to primary structures, ESA is engine of Ariane5’s first stage. The VEGA E collaborating with the Fraunhofer Institute development has successfully fire tested “Polymers make sense, since you have no may need tools to address specific and to investigate the possibility of using AM an AM thrust chamber that is fed by liquid loads in zero-G, but we also want to have unpredictable situations where the damage oxygen–methane propellants. metal printing capabilities,” Dr. Ghidini is such that standard tools don’t work,” he points out. “Metal spacecraft parts do fail, adds. “On the ISS, metal 3D printing could 3D printing to stay in space and we need to have repair opportunities.” also imply the ability to build satellites The MELT, Europe’s first 3D printer capable of printing aerospace-grade plastics in zero gravity. 17 These capabilities will be particularly directly in orbit instead of launching them. Additive manufacturing for space is quickly important for missions such as the Deep We could produce and deploy cubesats becoming a reality and the most logical next Space Gateway (now known as the Lunar without the cost of launching them from step is using it in orbit. Why? “Look at Apollo Orbital Platform-Gateway or LOP-G), which is Earth. And even expand structures that are 13,” Dr. Ghidini replies. “If they had a 3D printer the space station orbiting the Moon, that will already in orbit.” on board, they could have printed an adapter be ready in 2024 - so practically tomorrow - for the CO2 filter and everything would have and then the crewed mission to Mars. While the German Aerospace Center is been much easier. They managed, of course, currently researching a metal PBF 3D printer but the issue of replacement parts for long- Deep space missions would be unthinkable for space, the metal powder does bring a term missions remains.” For the past few without 3D printing capabilities. “It’s a whole set of challenges and considerations. years, two polymeric extrusion 3D printers completely enabling technology—especially That’s why Dr. Ghidini’s team is also working have been in operation on the ISS. ESA is for metals—because it’s not possible to bring on a metal wire-based 3D printer that building a metal 3D printer for space as well. all spare parts along and because astronauts will launch next year. The idea is to build

AM Focus 2020 Aerospace / Interview 39 “Look at Apollo 13, if they had a 3D printer can be produced from plants grown on the (EVA) on the Martian surface, or to treat on board, they could have printed an adapter way to Mars or on the Red Planet directly. burns caused by an accidental fire on board. The astronauts’ stem cells will also be used Because of astrodynamics, the mission to for the CO2 filter and everything would have to manufacture tissues and expose them Mars cannot be aborted: once it takes off, the to the same high levels of radiation they astronauts will have to go for the full two-year been much easier” would receive on the trip to Mars, for even tour, which means that if they get hurt, they longer periods of time, to characterize their will need to be able to fix themselves. response without exposing them to any risks. This information will be used to develop Mass production: the final frontier samples on Earth, then send the printer to product in space,” Dr. Ghidini says. “Imagine drugs to cure cellular damage, through a space and print the same parts with the having an unlimited supply of titanium, personalized medicine approach, which is a For the more immediate future, ESA is same parameters. By comparing the parts, a very noble metal that you can build strong trend on Earth as well. working on evolving current AM processes it will be possible to understand the quality structures with; aluminum, also very noble; and implementing future AM applications. that can be achieved in orbit. “This is really iron; and silicon for electronic components Printing bones and skin will also be “We will continue to work on fully integrated something that would change our way of production. It means having manufacturing necessary to cure the astronauts if they hurt design and manufacturing tools, to go doing space in the long run,” he concludes. capabilities and resources available on themselves during extravehicular activity from CAD to topology optimization and location while producing oxygen for the Out of Earth Manufacturing astronauts to breathe.”

Out of Earth Manufacturing is a program Dr. Ghidini’s team is also researching Bioprinting human tissue could help keep astronauts healthy all the way to that encompasses everything that can be extraction, intended as a form of circular Mars. An ESA project has produced its first bioprinted skin and bone samples.19 produced off our planet: on the Moon, on production. “A planetary lander exhausts satellites, or on Mars. This is the program its functions after landing,” he explains. “It that includes the bases that will be built out becomes a piece of junk on the planet’s of Martian and Lunar regolith, bringing us to surface. We can extract all metals and all the third domain for space AM applications: polymers from it to recycle and reprint them on-planet manufacturing. Dr. Ghidini’s into new structures to use in a new phase of team conducted tests on both Martian and the mission. The properties of the materials Lunar regolith simulants. For the Moon base, will decay,” he points out. “But that doesn’t they built a 1.5-ton demonstrator, and are matter as long as we take this into account considering two possible approaches: using when we engineer the new structures.” the Sun to sinter the regolith powder or phosphoric acid to bind it. Phosphoric acid is The last family of materials to consider for available on Mars but not on the Moon. And “Out of Earth Manufacturing”, and perhaps that’s not nearly all. the most important, is biomaterials. Using stem cells, a team in Dr. Ghidini’s division Lunar regolith has been investigated for bioprinted skin, bone tissue and vasculature 3D printing as a ceramic but Dr. Ghidini’s at minus one-G conditions (upside down), lab also found that aluminum, titanium, to demonstrate that the process could also steel and silicon can be extracted from it, work in zero-G. “The binder we used to hold releasing oxygen. “Which, of course, is not a the cells together is alginate, which comes byproduct, as much as it is a fundamental from algae,” he says, pointing out that it

AM Focus 2020 Aerospace / Interview 41 actuators through the use of 4D printing. introduction of a probabilistic approach “That’s a big step,” he concedes. “We can in part evaluation. “Together with Milan 3D print shape memory alloys that are Polytechnic University, we developed activated by temperature. This would allow a software called ProFACE that we will us to launch a folded structure that could use for structural evaluation of additively easily be contained in a small space, so manufactured parts,” Dr. Ghidini says. “It that it would unfold once it reaches the starts with probable defects of an AM part required temperature. By comparison, in and assesses the life of the components order to deploy complex structures in space, based on the probability of a failure. It’s a very today we use expensive and heavy motors new way of doing numerical assessment.” or dangerous pyrotechnics. These systems depend on their reliability, and they could fail. To boldly go where no AM part has gone On the other hand, memory alloy will always before, ESA will look to the industry for work because they only depend on physics.” faster machines, smart manufacturing and digital twin capabilities, modeling The final area is mass production. Space simulations and automated inspections. became a first adopter of AM because That’s a story the entire AM industry can of very limited batch requirements. But relate to as it evolves to help humans that is changing as satellite networks achieve one of the most exciting milestones

3D printed CubeSat with electrically conductive lines that have been laid down using ‘doped’ PEEK plastic feedstock.20 become larger constellations. “Not as large of all: human settlement in space. ◆ as automotive but closer to aeronautics volumes,” Dr. Ghidini admits. This opens up a whole new range of challenges and opportunities that take ESA closer to earthly 21 AM challenges. “We are going to need 3D printed CubeSat body made from ‘doped’ PEEK. through the AM process, considering all the mirrors and other high-stability structures. more advanced AI to implement machine limitations in terms of manufacturability, AM-specific titanium alloys will be developed learning in process monitoring, as well as support structures, residual stresses and to become stronger during the 3D printing more advanced NDI capabilities, all to be building strategy. We want to work on design process. Copper alloys are being studied for combined with more stringent requirements guidelines and handbooks to help designers. cryogenics as well as chemical propulsion on Cyber-Security in manufacturing,” he On the material side, we will continue the applications, using green lasers to process adds. Standardization will also become work on feedstock, powder and supply chain them. An entirely new area for AM is metallic increasingly important. control. We want to introduce metal powder glass composites. “These are very promising recycling in space AM, something we will materials for space, for their stability and Post processing, surface engineering, the need to address to further improve cost- stiffness,” Dr. Ghidini says. “We want to make use of 3D printing for the repair of both AM efficiency,” Dr. Ghidini explains. them available for additive manufacturing and non-AM parts, finishing capabilities for and use them in very long-lasting very complex parts: these are all key areas of New material development will be more AM mechanisms, aiming at ‘infinite life’.” focus at ESA. “My dream is to have a machine specific. For example, making aluminum evaluate—during the process - the impact on cheaper, stronger, as well as stress-corrosion- As the line between science and fiction the fatigue life of a component and decide cracking resistant. Or developing aluminum thins, Dr. Ghidini’s team is now looking whether to go for a repair or to accept the with up to 40-50% silicon content for to develop compliance mechanisms and part as it is.” This is made possible by the

AM Focus 2020 Aerospace / Interview 43 A drink among the stars on Spaceship Neptune

Space Perspectives’ balloon is expected to take off on its first commercial rides by 2024.22 An uplifting interview with Taber MacCallum, Co-CEO of Space Perspective

Led by Co-CEOs Taber MacCallum and Jane printing fits into this picture, we spoke with Poynter, both space industry veterans and life Mr. MacCallum on the occasion of the new support system experts, Space Perspectives company’s official launch. is the startup realizing the vision of taking people to the edge of space, aboard a MacCallum and Poynter are no strangers stratospheric balloon. to 3D printing. They also founded two other companies that make intensive use of these At about 100,000 feet above the planet’s technology: Paragon Space Development surface, Spaceship Neptune will give more and World View. Paragon is a company that regular people the opportunity to see the provides life support systems and other Earth, floating against the blackness of space, components for complex space structures such while sipping a cocktail from the comfort of as the ISS, or upcoming space vehicles such a private bar. Space Perspectives’ balloon is as Sierra Nevada’s Dreamchaser and Boeing’s expected to take off on its first commercial Starliner. World View was founded to bring rides by 2024 and—you guessed it—3D humans to space in a stratospheric balloon printing is going to play a big part in making however it shifted to using this technology to this happen. To understand exactly how 3D provide high quality stratospheric imagery

AM Focus 2020 Aerospace / Interview 45 through it. All that ducting and the vents that size end-up being key factors to determine “We broke the skydiving circulate the air will be 3D printed. So I do see success or failure of a startup. CAD programs a very large amount of 3D printing, not only are going a very long way in making people world record taking senior for shapes that we could not make otherwise and teams more productive. Many of these but also for weight optimization and for the programs are developed specifically with Google executive Alan Eustace possibilities that this technology offers to use additive manufacturing in mind. We recently materials that are very hard to machine. started using Onshape and it has enabled us to set up online collaborations with several to 40 km above the Earth.” 3dpbm: Do you think that 3D printing is one people working on a part and the inherent of the reasons why so many startups are process management. emerging in the new space economy? SaaS—and now MaaS with 3D printing—are TM: There is no doubt that AM is an enabler. opening up new possibilities to address services. As the technology and materials 3dpbm: How will this knowledge be Keeping to schedule and containing the team projects that would otherwise be too continue to evolve, they will play an even applied to the Spaceship Neptune greater role in the development of the project?

Spaceship Neptune capsule. 3D printing can be used for life support systems, as well as for TM: 3D printing is not only cheaper than plumbing and ducting systems in the Space Perspectives’ capsule.23 3dpbm: Let’s get right to it. Why is 3D printing producing parts with molds, it is also a necessary for making this project a reality? lot faster. Especially if we use internal machines. Based on my experience, our Taber MacCallum: Let me start by giving plans are for about 25% of the printed you an actual example: a project we parts we need to be made in house, and conducted with Paragon Space Development to outsource the rest to the large service Corporation. In 2014 we broke the skydiving bureaus, depending on the quantities and record taking senior Google executive Alan material requirements. Eustace, who is a pilot and expert skydiver, to 40 km (25 miles) above the Earth. 3dpbm: Have you already identified the parts that may be 3D printed in the new He used a specially designed space suit, capsule? reaching speeds of more than 1,300km/h. Many parts of the suit were custom made TM: We are not far into it, but I imagine and 3D printed, including the entire control there will be several. In general, I think that system in the front. It wasn’t just a matter of we will need to have a lot of 3D printed customizing the parts, but also the ability to ducts. These will be used, for example, in produce multiple iterations, very quickly. the complex structure needed to support the full-size windows that let guests get There is a whole range of systems that will the full view of space around the Earth. In benefit from additive manufacturing in space, order to make sure they don’t get clogged not just for life support but also for many up at -80°C, we will need to keep the types of plumbing and ducting components boundary layer next to the glass moving all inside the capsule. the time, so there will be a lot of air flowing

AM Focus 2020 Aerospace / Interview 47 Spaceship Neptune will make intensive use of 3D printing to produce the ducting elements.

This is needed to ensure sufficient air circulation and keep the large windows clear, with outside temperatures of -80°C 24 This will not be a pressurized capsule but Seeing the Earth from space can be an it will be a full-scale test to the full altitude. enlightening experience and that’s exactly Within two and a half years we are looking what many astronauts report. Additive to launch the first uncrewed pressurized manufacturing will help us make this project capsule and in three and a half years we are a reality while containing costs. The very first looking to start human test flights. Within flights will likely cost no less than $100,000 four and half to five years we expect to start per person. It will be an opportunity for commercial operations. corporations, organizations and artists, as well as educational opportunities. We are in 3dpbm: Who will be able to go on Spaceship touch with an organization called Space for Neptune? Humanity which shares our same goals of expanding access to space. As demand grows, TM: Let’s be clear, our goal is to make space a priority is getting costs down so that even accessible to as many people as possible. more people will be able to experience it.

The Neptune Spacecraft will take up to eight passengers as well as research payloads on a six-hour journey to to stratosphere.26

Space Perspectives wants to make its flights to space as accessible as possible.25

expensive. It’s the combination of good parts but it can be also used to shape parts in structural and thermal analysis tools with new order to make better systems. Our spacecraft generation CAD tools that are easy to use and – and any aircraft - is a perfect example of a to learn. Startups that are born with these very integrated system. When you tweak one practices have an advantage over companies part you need to tweak a number of parts using more traditional approaches. connected to it. 3D printing lets you create parts that can enable optimized systems, and 3dpbm: What are the limits of these software needs to help engineers seamlessly technologies? optimize these systems.

TM: I wouldn’t talk about limits as much 3dpbm: With this in mind, what is your as further improvements. In order to fully timeline now? leverage the benefits of AM, the software still needs to improve in terms of systems TM: We will run the first uncrewed test of engineering. AM doesn’t just make better Neptune by the first quarter of next year.

AM Focus 2020 Aerospace / Interview 51 Ground control to major AM

SpaceX made history flying NASA astronauts Doug Hurley and Bob Behnken to space aboard its Crew Dragon spacecraft.27

These 18 companies are pushing the space industry forward with the help of 3D printing SpaceX Rocket Lab Founded by Elon Musk, an outspoken Originating from New Zealand and now also supporter of AM as a production process, operating out of California, Rocket Lab has the company has repeatedly achieved the been developing its space vehicle, Electron, impossible: first by landing rockets (with since 2013. The rocket’s first stage nine 3D printed parts) and reusing them, and Rutherford engines are the first oxygen/ now as the first private company to launch kerosene electric turbo-pump-fed engine to humans into space. SpaceX was also one use 3D printing for all primary components. of the very first companies to present In July 2019, Rocket Lab completed the additively manufactured rocket engines: production of its 100th Rutherford engine, the SuperDraco engines used in the launch 70 of which have already been launched into recovery emergency system. This happened space on Electron missions. over five years ago and has helped dozens of other companies—not only in space— Relativity understand the benefits of metal AM and Media (and investor) darling Relativity has its reliability as a manufacturing process for made headlines for its unique approach to 3D advanced, high-performance parts. printing entire rockets using a gigantic robotic

AM Focus 2020 Aerospace / Mapping 53 Relativity Space now has launch partnerships on both coasts, in Florida and in California.28

agreement with NASA’s Stennis Space Center the most difficult engine parts to develop in Mississippi to test its 3D printed engines at while keeping manufacturing time short and the E-1 test stand to evaluate and test fire its cost low. E-2 engine for small launch vehicles. Blue Origin Virgin Orbit Founded by Amazon’s Jeff Bezos, Blue Origin Although it suffered a failure in its attempt uses AM more than just about any other to launch a rocket from a modified flying space company we are aware of. During the 747, Virgin Orbit is also working with AM in COVID-19 crisis, Blue Origin showed batteries interesting ways. The company acquired of Stratasys and Raise 3D polymer 3D printers one of the first hybrid additive-subtractive churning out face shield holders. However, its manufacturing machines in the world use of AM is very much targeted toward space through a partnership with DMG Mori, and applications. In fact, the company was just used it with NASA to study the use of AM to selected to be part of NASA’s Artemis program build multimetallic combustion chambers. to return humans to the Moon. The project is The punishing operating environment of based on the Blue Moon Lander’s BE-7, which combustion chambers, makes them one of has “almost entirely 3D printed” engines.

A sample of hardware built in Virgin Orbit’s hybrid additive-subtractive manufacturing machine.29

directed energy deposition system called Scotland-based company (apparently Scotland Stargate. The company raised an incredible is the Colorado of the UK) revealed that it $140 million to achieve its goals, which are manufactured the world’s largest metal rocket now closer than ever. Relativity just moved engine 3D printed in a single piece, using the into a new 120,000 sq. ft. space in Long SLM800 metal 3D printer from German AM Beach that will house an unprecedented company SLM Solutions. manufacturing facility. Relativity integrates machine learning, software and robotics with Launcher metal additive manufacturing technology Based in NYC, Launcher specializes in rockets and is working to produce its first Terran 1 3D for satellite delivery and has produced the printed rocket. largest single 3D printed part with support from the specialists at EOS Group’s AMCM: Orbex an 86-cm-tall copper alloy 3D printed rocket This is not just any space company. As a low- engine combustion chamber for its E-2 rocket cost orbital launch services company serving engine. The part was 3D printed on AMCM’s the needs of the small satellite industry, Orbex M4K machine and it is the world’s largest liquid has developed one of the most advanced, rocket engine combustion chamber 3D printed low carbon, high-performance micro-launch in a single part, with an exit nozzle diameter vehicles in the world. In 2019, the Forres, of 16 inches (41 cm). Launcher entered into an

AM Focus 2020 Aerospace / Mapping 55 Masten’s Kyle Nyberg observes the Xombie vehicle on the Astra performance capabilities. The new chamber Masten Space Systems pad prior to flight test operations. Xombie won the Level Astra prides itself on not using 3D printing. As design is made up of only two primary copper Masten Space Systems is a California-based One, second place prize of $150,000 in the 2009 Lunar 31 Astra Co-founder Chris Kemp stated: “Rather parts and takes just under a month to print aerospace startup specialized in vertical Lander Challenge. than rely on costly 3D printing or labor using SLM technology, reducing overall lead takeoff and vertical landing rockets. The intensive composites, we make the rocket as times by several months. Aerojet Rocketdyne company recently demonstrated an electric inexpensively and as streamlined as possible, is applying 3D printing technology to many fuel pump 3D printed by Elementum 3D and using lightweight aluminum.” However, they of its other products, including the RS-25 made out of its A6061-RAM2 alloy. The 3D do use 3D printing: the impellers for pumps engines that will help explore deep space, and printed e-pump is part of Masten’s mission and rocket engine chambers in the Rocket 3.0 the company’s new AR1 booster engine. for the NASA Artemis Program, which has the (Astra’s latest launch vehicle) are additively goal of bringing humans back to the moon. manufactured. Kemp points out that “3D United Launch Alliance Just last April, Masten Space Systems was printing is the slowest and most expensive Colorado-based ULA is one of the biggest chosen by NASA to deploy eight payloads to way to make almost anything.” That is true for names in space and also a very important the moon’s South Pole in 2022: a major step in most parts, and Astra uses 3D printing only adopter of AM. The company is a 50-50 joint laying the foundation for human expeditions for those parts where they cannot achieve a venture between Lockheed Martin and The to the moon as soon as 2024. lower cost otherwise. A very logical strategy. Boeing Company, formed in 2006 to provide reliable, cost-efficient access to space for U.S. Skyrora Aerojet Rocketdyne government missions. It brings together two Skyrora Ltd. is an Edinburgh-based space & Design Technologies (PADT) on 3D printed Sacramento-based Aerojet Rocketdyne of the launch industry’s most experienced and company that has successfully tested a 3D parts for NASA’s Orion deep-space spacecraft. has been working over the last decade to successful teams—Atlas and Delta—that have printed rocket engine powered by an ecological Key to the project are Stratasys’ advanced incorporate 3D printing into the RL10 and supported America’s presence in space for liquid fuel made of plastic waste. The ground materials—including an ESD variant of the other propulsion systems to make them more than 50 years. Among the most relevant tests, which were carried out in Fife, Scotland, Antero 800NA, a PEKK-based thermoplastic more affordable, while taking advantage recent initiatives involving AM, ULA recently mark an exciting breakthrough in the space offering high performance mechanical, of the technology’s inherent design and partnered with Oerlikon AM for additive launch segment and could pave the way to chemical and thermal properties. manufacturing and qualification of flight a more sustainable industry. Skyrora recently components for the next-generation Vulcan evaluated the innovative fuel, called Ecosene, Airbus Centaur rocket. using its 3D printed 3.5kN LEO engine. After Along with the Crew Module (CM)

Testing of the Made In Space 3D printer involved 400- conducting static horizontal firings using both manufactured by Lockheed Martin, the Orion plus parabolas of microgravity test flights.30 Made in Space the Ecosene fuel and standard kerosene fuel, spacecraft consists of the European Service Made in Space was the first company to the Scottish company reported promising Module (ESM) manufactured by Airbus send a 3D printer to the International Space results for its eco-friendly alternative. Defence and Space. The third European Station and actually use it to print tools Service Module (Artemis III Mission) will be (it’s now standard procedure). Since then, Lockheed Martin used to fly astronauts to Earth’s neighbor in Made in Space has made headlines with Denver-based Lockheed Martin is the reason space in 2024—the first to land on the Moon several fascinating space-based additive why Colorado is becoming a hub for the since Apollo 17 over 50 years ago. In fact, Airbus manufacturing projects. In January, the young commercial aerospace industry. The has been a key ESA partner for maturing company moved its corporate headquarters company has several activities in aerospace additive manufacturing technologies for space and satellite manufacturing operations to and defense, and it is also building the crew applications since the very beginning. The Jacksonville, Florida where it will continue to module for the Orion spacecraft, which company worked on a number of projects, work on Archinaut One, an in-space system could bring humans back to deep space and including the evaluation of all 3D printable capable of performing additive manufacturing eventually the Moon. Lockheed Martin is parts of rockets for ESA missions and 3D and robotic assembly. working with Stratasys and Phoenix Analysis printing an entire platinum thruster in 2015.

AM Focus 2020 Aerospace / Mapping 57 Consultancy

Unlock The Bigger Picture The Boeing CST-100 Starliner spacecraft is guided into position above a United Launch Alliance Atlas V rocket on November 21st 2019. 32

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Boeing Thales Alenia Space opportunities and potential U.S. aerospace giant Boeing is working on With the launches of the Telkom 3S, SGDC the CST-100 Starliner, the vehicle that is and KOREASAT-7 satellites, plus satellites competing with SpaceX’s Crew Dragon for in the Iridium Next constellation, Thales Market Analysis Vertical Marketing Go To Market commercial human space flight. Though Alenia Space had already sent into orbit 79 Brand Messaging White Papers Case Studies the Starliner failed to reach orbit in a recent metal additively manufactured parts and uncrewed flight test, the company and its 350 polymer tube supports for chemical partner NASA are still set on moving forward. propulsion systems as of 2017. In 2019, the The Starliner integrates a number of PEKK 3D French-Italian company further scaled up printed parts after a partnership was signed additive manufacturing adoption by turning with Oxford Performance Materials’ aerospace out 3D printed components for telecom Get in touch division (which is now owned by Hexcel and satellites built on its all-electric Spacebus Neo goes by the name of HexAM). platform. ◆ Special Thanks

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