In a groundbreaking move to push the limits of metal additive manufacturing (AM), MELD Manufacturing Corporation has entered into a research collaboration with the National Institute for Aviation Research (NIAR) at Wichita State University (WSU). This partnership aims at driving significant advancements in aerospace manufacturing technologies, with wider implications for the additive manufacturing industry. MELD, headquartered in Virginia, is known for pioneering technologies that reshape traditional manufacturing norms. The collaboration with NIAR symbolizes a concerted effort to elevate aerospace manufacturing technologies to new heights. This synergistic endeavor is expected to provide substantial benefits not only for major corporations but also for small- and medium-sized enterprises by promoting the adoption of advanced manufacturing processes.
Partnership to Propel Aerospace Manufacturing
MELD Manufacturing Corporation’s innovative approach to metal additive manufacturing finds a fitting partner in WSU’s NIAR, an institute recognized for its significant contributions to aviation research. The collaboration is underpinned by the award from the EDA Build Back Better Regional Competition, emphasizing the initiative’s robust financial and strategic foundation. This funding bolsters the development and validation of manufacturing technologies that align with the aerospace sector’s exacting standards. By providing its state-of-the-art K2 3D printer to NIAR, MELD aims to set new benchmarks for production efficiency and quality. This printer represents MELD’s largest enclosed additive-only system, and its deployment signifies a monumental step towards integrating advanced manufacturing into conventional aerospace production lines.
The primary objective of this collaboration is to enhance and validate technologies specific to aerospace manufacturing. Such advancements are expected to propel the sector towards greater heights of innovation and efficiency. Moreover, by focusing on the needs of small- and medium-sized businesses, the partnership aims to broaden the accessibility of cutting-edge manufacturing technologies, fostering a more inclusive technological ecosystem within the aerospace industry. This initiative will also involve rigorous testing and validation processes, ensuring that the technologies developed meet the stringent certification standards necessary for aerospace applications.
Revolutionizing Manufacturing with AFSD Technology
A standout feature of this collaboration is the use of MELD’s proprietary additive friction stir deposition (AFSD) process. The AFSD process is a scalable, solid-state technology that allows for the creation of high-quality metal parts without the need for melting. This method, which operates in an open atmosphere, eliminates the need for specialized chambers or vacuum environments, thereby significantly simplifying the production process. Furthermore, the AFSD process enables the production of parts with wrought properties, making it ideal for manufacturing high-performance aerospace components. This innovative process promises to be a game-changer in the manufacturing world, offering a more streamlined and efficient method for producing large metal components.
The ability to produce metal parts with the desirable properties of wrought metal, but without the complexities and limitations of traditional methods, opens up new avenues for aerospace manufacturing. Since the AFSD process does not require melting, it can create parts that are free from common defects associated with melting and solidification, such as porosity and shrinkage. This results in higher-quality parts that can withstand the demanding conditions of aerospace applications. Moreover, the open-atmosphere operation of the AFSD process reduces the need for energy-intensive and costly environmental controls, further enhancing its appeal as a manufacturing solution.
Features and Capabilities of the K2 3D Printer
Delivered to NIAR, the K2 printer embodies MELD’s commitment to innovation in metal additive manufacturing. With a substantial build space of 81.6 cubic feet, the K2 printer is capable of rapidly fabricating and repairing large metal components. This capability is particularly advantageous for the aerospace sector, where the demand for large-format titanium and aluminum structures is continually growing. The K2 printer’s ability to produce these components efficiently positions it as an invaluable tool for meeting the aerospace industry’s evolving needs. Furthermore, the K2 printer’s continuous feed system for standard-sized solid metal bars minimizes manual intervention, allowing for a more efficient and seamless AFSD process.
The continuous feed system not only enhances productivity but also reduces the risk of interruptions and errors during the manufacturing process. This is crucial for maintaining the high standards of quality required in aerospace applications. Researchers at NIAR will utilize the K2 printer to test, validate, and set certification standards for various specifications critical to aerospace manufacturing. These efforts will pave the way for new industry standards, ensuring that the technologies developed through this collaboration are capable of meeting the rigorous demands of modern aerospace applications.
Advancing Aerospace through Strategic Collaboration
The collaboration between MELD and NIAR addresses the growing demands for advanced manufacturing technologies within the aerospace sector. By integrating the capabilities of the K2 printer and the AFSD process, the partnership aims to enhance the efficiency and performance of manufacturing essential flight components. This initiative represents a significant leap forward in the aerospace industry’s pursuit of innovation and excellence. The ability to produce large metal components with the desired properties more efficiently is expected to yield substantial benefits in both the short and long term. Furthermore, MELD’s solid-state process has shown significant potential in the military and defense sectors, industries known for their high standards and rigorous demands.
This proven track record underscores the strategic importance and applicability of MELD’s technology in various high-stakes industries. The partnership with NIAR not only strengthens MELD’s position in the aerospace sector but also highlights the broader applicability of its technologies. By addressing the unique challenges and requirements of aerospace manufacturing, MELD and NIAR are setting the stage for future advancements that will continue to push the boundaries of what’s possible in metal additive manufacturing.
Wichita: The Heart of Aerospace Innovation
A notable aspect of this collaboration is the use of MELD’s proprietary additive friction stir deposition (AFSD) process. This scalable, solid-state technology creates high-quality metal parts without the need for melting, operating efficiently in an open atmosphere without specialized chambers or vacuum environments, simplifying production. The AFSD process produces parts with the desirable properties of wrought metal, making it perfect for high-performance aerospace components. This innovative method stands to revolutionize manufacturing by offering a more streamlined and efficient way to produce large metal components.
The ability to manufacture metal parts with wrought properties while bypassing the complexities and drawbacks of traditional methods opens new doors for aerospace production. Since the AFSD process doesn’t involve melting, it avoids common defects like porosity and shrinkage, resulting in superior quality parts capable of withstanding rigorous aerospace conditions. Additionally, its open-atmosphere operation minimizes the need for energy-intensive and costly environmental controls, further enhancing its appeal as a cutting-edge manufacturing solution.
