3D printing is fast changing the manufacture of aviation parts and the aviation industry as a whole. Now, with the apparent ability to print parts using combinations of over a hundred different materials including titanium, aluminium and steel, creating parts to fit a private jet charter type of aircraft such as the Jet Stream is becoming as simple as hitting the print button. In 2011, the first 3D printed ‘snap together’ plane was unveiled and flown to demonstrate its abilities and the future possibilities for aviation. Manufactured by SULSA (Southampton University Laser Sintered Aircraft), the aircraft has a 6.5 foot wingspan, so this was only a small scale model. However, with a maximum speed of around 100 miles per hour, the craft took only 7 days to complete from design to take off and was created with a budget of just £5,000. So the proof of concept aspect of the project was more than achieved. So how does this apply to the civil aviation industry? Being lighter and stronger than traditionally manufactured pieces, the parts can also be created with a much shorter lead time and require a smaller manufacturing area, giving an all-important advantage over traditionally manufactured pieces – reduced factory space. Parts created with the 3D technology will be seen in commercial use by 2016, with a 3 meter wing span being used in the manufacturing of a passenger plane set to go into service sometime that year. Companies such as GE Aviation are also working on improving the speed of their printing process to further increase the manufacturing advantages, applying the improved production rates to their advanced fuel nozzles (capable of withstanding temperatures of around 3,000 degrees) for use within the CFM International Leap engine, which is currently due to enter service in 2016. Also, through printing the parts, the need to mill the parts from larger pieces of metal is removed, making each part more ecologically viable. Through technologies such as these, corporate and commercial jets also gain the advantages of increased performance and safety. NASA is already planning on sending a 3D printer to the international Space Station where over 30% of the parts and tools needed by the astronauts can be manufactured on the space station its self. Greatly reducing the waiting time and fuel used when sending equipment from earth. So with such major players running with the development of this cutting edge technology, the private jet charter industry can look forward to some significant advances in the coming years. Jerry writes for Private Jet Central, a private jet hire and Private Jet Charter organisation.
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