Aircraft Ducts 3D Printed in Composite Instead of Metal | The Cool Parts Show Ep.68

Air handling ductwork in an aircraft has to meet many performance requirements at once. They include electrostatic resistance, flame resistance, chemical resistance and resistance to vibration, not to mention the requisite strength of the part - all in a form complex enough to snake around and through other elements of the aircraft. Formed aluminum ducts have satisfied the need historically, but Eaton’s Advanced Materials and Process Group is developing a different solution. With 3D printed polymer, ducts could be manufacturing with less cost, less lead time, less part weight and more design freedom. The key is a polymer material satisfying all the design requirements. Eaton’s solution is a carbon-fiber-reinforced PEKK tailor-made by the company for this application. Watch this episode of The Cool Parts Show to learn how Eaton is preparing for the future of aircraft duct production.
This episode of The Cool Parts Show brought to you by Carpenter Additive. www.carpenteradditive.com/
FOR ALL ACCESS MEMBERS: When 3D printed ducts are in full production for future aircraft, the design of 3D printers may need to change. Eaton engineer Si Chen describes the advances she anticipates. The Cool Parts Show All Access is a free subscription for fans of the show. Sign up and watch this month's exclusive Extra here: www.additivemanufacturing.med...
LEARN MORE ABOUT:
An existing Eaton success with AM for part production: 3D printing of metal aircraft parts
www.additivemanufacturing.med...
PEKK, PEEK, and the differences between these polymer materials
www.additivemanufacturing.med...
Pellet-fed Titan 3D printer from 3D Systems
www.3dsystems.com/ext-titan-p...
Another duct made through 3D printing - this one optimized for air flow
www.additivemanufacturing.med...
3D printed polymer replacing metal in a bracket for a helicopter
www.additivemanufacturing.med...
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[@AdditiveManufacturing]

FOR ALL ACCESS MEMBERS: When 3D printed ducts are in full production for future aircraft, the design of 3D printers may need to change. Eaton engineer Si Chen describes the advances she anticipates in our ALL ACCESS EXTRA at www.additivemanufacturing.media/kc/cool-parts/articles/eaton-duct-the-cool-parts-show-all-access?

[@dhanadevi6684]

Mam can we make air duct using wood -pla filament is it possible? And it can be applicable in automobile industry?

[@enkidu9989]

Certainly they could be a lot smaller around the x and y axis.

[@enkidu9989]

I would love to see how they test the piece for it's ability to withstand constant vibration for the expected lifespan of the aircraft and also would like to know how the part is fixed in position so we can speculate on potential stress areas.

[@willofthemaker]

Just 12 hours to print that big duct? Damn thats quick.
Curious how the layer lines affect the airflow

[@phildand6620]

Depending on their protrusion and peak to peak distance, they may help air flow by creating a layer of air between those peaks and decreasing the frictional forces via air on air rather than sticking more to the surface itself (like a golf ball a bit).

[@willofthemaker]

@@phildand6620 would be really interesting to see that comparison made. If that is the case, layer lines would help improve efficiency of ICE cars

[@trashpanda9433]

Eaton is going to have a heck of a time getting PEKK materials like that to print well. They have extremely high contraction during cooling that is further worsened with the high temps needed for these prints. So the issues with these types of parts are going to be significant hoop stress that limits total comparative strength, warping on any flat areas, curl on any sharp corners, and dealing with variable crystallinity for the differential cooling rates during printing. Not even getting to the issue with volumetric air flow and deltaT in the printing enviroment.

[@UrSoMeanBoss]

Pete's smile is very contagious

[@raulkaap]

In the All Access extra, the printer head is uncensored. Parental discretion is advised.

[@AqibKhan-xf8vo]

What is price of that part? How much economical benefits?

[@IkarimTheCreature]

Is this part abrasive flow machine before being put into service, or how are they dealing with the internal smoothness of fdm prints?

[@Tasijoe]

Great episode!

[@AqibKhan-xf8vo]

My favorite show ❤

[@Hteja96]

What about watertightness? One bad layer and you may leak air. Interested to see if there’s a workaround.

[@deepak_nigwal]

she (person from Eaton) said the nano-composites act like sealants while bonding with layers while printing.

[@sabercruiser.7053]

Favorite show ❤❤✨✨😁😁👍👍🌹🌹👌👌 thank you much greatful

[@markbass_trojanthinking]

🎉

[@TheBeddoeFamily]

My dudes..."3D printed in composite instead of metal"
This is The Way. Maybe not ALL ways, but a LOT of ways.

[@-1-2-1-]

FDM parts in commercial aircraft?! I hope these ducts are not safety critical!

[@avenuex3731]

Ok. Look. They are putting chopped up carbon fiber in PET. Not a real big deal.

[@Oscaromann]

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