Sector
3D Printing / Aerospace

Societal benefits
The development of a new generation of quieter aircraft engines.

Mandate
Develop and manufacture a new 3D printing technology to extrude very high viscosity epoxy resins. The extrusion is composed of 26 independent and simultaneous filaments of max. 200μm in diameter. This technology is specifically intended for printing structures to reduce the noise level generated by aircraft engines. The printer head is installed on a robot and allows printing on complex three-dimensional surfaces.

Development time
17 months

Technological advancements

• High-pressure, low-flow hydraulic system
• Fabrication and welding of micro metal channels
• Operation in flow mode rather than pressure mode
• Compatible with all robotic systems

Scientific advancements
Technological breakthrough in 3D printing

Specs

• Print head weight: 35 lbs [15 kg]
• Hydraulic unit weight: 250 lbs [115 kg]
• Extrusion pressure: 9500 psig max. [65 MPa]
• Control pressure: 3000 psig max. [20 MPa]
• Linear print speed: 3/8″ to 4 in/s [10-100 mm/s]
• Number of simultaneous filaments: 26
• Extruded filament diameter: 0.010″ [200μm] / inter-filament spacing 0.032″ [800μm]
• Displacement system: 6 axis Fanuc Robot with 55 lb [25 kg] payload
• Printing table: 60″ x 34″ [1.5 x 0.9 m] / 425 lbs [195 kg]
• Security enclosure: 144″ x 150″ x 90″H [3.7 x 3.8 x 2.3 m] / CSA-Z434 Certified