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Stratasys Partners with Aurora Flight Sciences to Design & Develop World's First 3D Printed, Jet Powered Aircraft

Aurora Flight Sciences in Manassas, VA has been developing unmanned aerial vehicles (UAVs) for both the civil and military markets for nearly three decades. However, with advancing customer needs and requirements, its research and development center is utilizing Stratasys® 3D printing technology more frequently for production parts and tooling to help bring new innovations to unmanned flight.

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KMC Reduces Instrument Part Cost & Lead Time Through Direct Digital Manufacturing with Stratasys Technology

Kelly Manufacturing Company (KMC) manufactures the R.C. Allen line of aircraft instruments and is the world’s largest manufacturer of general aviation instruments. The R.C. Allen line includes air and electric–attitude gyros, directional gyros, turn and bank indicators, turn and slip indicators, turn coordinators, tachometers, engine gages, voltage warning systems, battery probe assemblies and voltage inverters. Instrument manufacturing requires stringent testing facilities and a solid quality system to ensure that aircraft pilots have functional and reliable systems for a safe flight.

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Leptron Develops Unmanned Aerial Vehicle Using FDM Technology, Slashing Development Time & Cost

When designing the RDASS 4, Leptron engineers faced the challenge of developing eight variations of complex fuselage components in a short period of time to beat potential competitors to market. "We investigated various rapid prototyping technologies and discovered that the FDM process could provide components that met the mechanical requirements for all of our plastic fuselage components,” said John Oakley, Chief Executive Officer of Leptron.

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Top Flight: Piper Aircraft Creates Hydroforming Tooling with Fortus Technology, Cutting Costs & Lead-Times

Fred Jones, Lead Tool Designer for Piper, had the idea of using Fused Deposition Modeling (FDM) tools. FDM Technology is an additive manufacturing process that builds plastic parts layer by layer, using data from CAD files. He determined that FDM polycarbonate (PC) could withstand hydroforming pressures ranging of 3,000 to 6,000 psi, suitable for forming all of the structural parts produced by Piper. For hydroforming applications involving higher pressures, ULTEM 9085 hydroforming tools can withstand up to 10,000 psi.

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Trial & Air: Designing a 3D Printed Aircraft by Combining the Discovery Method with Stratasys Technology

Inspired by an Air Force defense program, SelectTech Geospatial proved that an innovative company could make a UAS (unmanned aerial system) quickly and with limited resources. SelectTech’s test flight also marked the first time a 3D-printed UAS took off and landed on its own gear.

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Connecticut Corsair Restores a WWII AirCraft to Flying Condition By Blending Traditional Techniques with FDM

Twenty years of passion for aviation led Craig McBurney to the F4U-4 Corsair with the hopes of restoring the World War II aircraft to flying condition. The Corsair was the only fighting WWII plane designed and built in Connecticut by one corporation, today’s United Technologies Corporation. In May 2005, it was declared the state aircraft by a unanimous vote of the state legislature, and today additive manufacturing technology is bringing it back to life.

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Aerialtronics Reduces Design and Development Costs, While Catering to Customization, With Stratasys 3D Printing

Unmanned aircraft systems (UASs) for civilian commercial applications are one of the most exciting disruptive technologies today. With more than 200 of its aircraftalready in use, Netherlands-based Aerialtronics is poised to offer systems for applications ranging from infrastructure inspection and mapping to livestock monitoring and creative filming for advertising and marketing.

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NASA Mars Rover - 3D Printing a Space Vehicle with Stratasys Technology

To design such a tenacious and specialized vehicle, NASA engineers drew on ingenuity and advanced technology. For example, about 70 of the parts that make up the rover were built digitally, directly from computer designs, in the heated chamber of a production-grade Stratasys 3D Printer. The process, called Fused Deposition Modeling (FDM) Technology or additive manufacturing, creates complex shapes durable enough for Martian terrain.

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Bell Helicopter Creates 42 Conduit Models in Just over Two Days with Stratasys Production Series 3D Printers.

Aerospace technicians are a demanding bunch and those at Bell's prototyping lab appreciate the clean post-processing of Fortus prototypes. They note other processes require three times more post-processing time than in actual part creation. Plus, Fortus systems allows for more iterations and better-designed components.

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GTRE Cuts Time to Prototype Jet Engine from 1 Year to 6 Weeks with FDM Technology

The Gas Turbine Research Establishment (GTRE) of Bangalore , India is a government laboratory whose primary function is research and development of marine and aeronautic versions of gas turbines.

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Direct Digital Manufacturing Reduces Part Costs 66% and Shaves 7 weeks Off Production Time for DST Control

DST Control reduced time-to-market and development costs for its electro-optical gimbals for unmanned air and ground vehicles. The combination of traditional and in-house parts production delivers customized units in half the time.

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Hybrid Rocket Engines Leverage Additive Manufacturing to Combine the Advantages of Solid and Liquid Propellants

Rocket Crafters, Inc. was founded in October 2010 by Paul Larsen, Ron Jones and Steve Edwards. Rocket Crafters’ Direct-Digital Advanced Rocket Technology (D-DARTTM), which is protected by a pending patent, employs the unique advantages of additive manufacturing, including its ability to create complex structures with unprecedented accuracy, to manufacture high-performance hybrid rocket fuel grains. Unit production costs are estimated at 50% lower and delivery times are expected to be 60% better than competing hybrid rocket motors that are made using manual casting methods.

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Evektor Saves up to 80% of Prototyping and Production Costs Using Fortus

The Evektor team needed an in-house solution with a build capacity large enough to accommodate the production of these parts. In addition, its development of unique end-use parts, such as blowpipes, required a special flame retardant thermoplastic; Evektor needed to invest in a production system that was compatible with such materials.

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DDM Takes Flight: FDM Direct Digital Manufacturing Saves $800,000 & Three Years Development Time

The TDF uses direct digital manufacturing to fabricate a wide majority of its training products. To do so, it employs four FDM additive fabrication machines in a centralized location with AFSO 21 (Lean) processes incorporated into the overall process.

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