Innovation at 30,000 Feet: 3D Printing and Aerospace Technology

While technology has not quite mastered the art of dematerializing transporter used in "Star Trek," engineers have figured out how to reliably transmit an object from conceptual digital space into physical reality. Developments in 3D printing and forward-looking innovations in the aerospace industry enable computer modeling of sleek components to bring about a transformation in the aerodynamic sector. This partnership will have massive positive connotations for the future of airborne travel both in Earth's skies and beyond. This is possible due to the advent of technology that was not conceivable a scant decade ago.

Walls and Widgets

Additive manufacturing is a style of 3D printing that "builds" a piece using a medium instead of carving it out. It has been very successful for companies such as McFarlane Aviation, according to the industry website 3Ders.com. In McFarlane’s sizable warehouse, crucial components, such as fuel nozzles and cabin-wall partitions, are custom-made for major airlines and airplane manufacturers. The additive manufacturing method offers unprecedented flexibility to the process, a true boon for the always-under-construction flight industry. Imagine the ability to print a beta-test model of cabin design for customer feedback without committing a fleets' worth of material contracts. With this one-off manufacturing method, it is a decidedly viable reality.

Printing-Up Efficient Fuel Use

With costs from passenger tickets to dimensional air freight calculated on the price of airplane fuel, getting the most out of every drop is understandably vital. Thanks to GE's inventive 3D-printed sensor housings, notes 3DPrint.com, airlines are getting a more detailed look than ever before at the performance of their engines. This data not only helps the current range of aviation engines to achieve peak performance, but also provides the future generation with better engine design options. This results in more efficient fuel use at every stage and hopefully lowered costs to pass on.

Seating Solutions On-The-Go

The problem with designing an airplane seat is that the idea of comfort varies from person to person. Stratasys Direct Manufacturing states that 3D printing may be the solution to aviation seat woes, both in design and turnover. The use of additive manufacturing to design prototype plane seating, armrests, and others increases their efficiency and creates a more durable framework. This method ensures high-quality airline-seating solution as well as aids airline companies to replace worn-out and broken components without disrupting their flight schedule.

What will the future hold for 3D-printed aerospace components? Provided that the facilities are large enough and teams perform sufficient testing, it is not inconceivable that an entire 3D printed plane may fly the skies in this generation. The key to making this high-flying dream a reality involves support and collaboration between the additive-manufacturing industry and airplane manufacturers, both notoriously secretive when it comes to proprietary knowledge. With such a bright future at stake and numerous steps already taken in the right direction, it may not be as steep a takeoff as a casual glance would 

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