Australia researchers create 'world's first' 3D-printed jet engines

(Reuters) –

Australian researchers unveiled the world’s first 3D-printed jet engine

on Thursday, a manufacturing breakthrough that could lead to cheaper,

lighter and more fuel-efficient jets.
Engineers at Monash University and its commercial arm are making top-secret prototypes for Boeing Co,

Airbus Group NV, Raytheon Co and Safran SA in a development that could

be the savior of Australia’s struggling manufacturing sector.

“This

will allow aerospace companies to compress their development cycles

because we are making these prototype engines three or four times faster

than normal,” said Simon Marriott, chief executive of Amaero

Engineering, the private company set up by Monash to commercialize the

product.

Marriott

said Amaero plans to have printed engine components in flight tests

within the next 12 months and certified for commercial use within the

next two to three years.

Australia has the potential to corner the market. It has one of only three of the necessary large-format 3D metal printers in the world – France and Germany have the other two – and is the only place that makes the materials for use in the machine.

It is also the world leader in terms of intellectual property (IP) regarding 3D printing for manufacturing.

“We

have personnel that have 10 years experience on this equipment and that

gives us a huge advantage,” Marriott told Reuters by phone from the

Avalon Airshow outside Melbourne.
3D

printing makes products by layering material until a three-dimensional

object is created. Automotive and aerospace companies use it for

producing prototypes as well as creating specialized tools, moldings and

some end-use parts.

Marriott declined to comment in detail on Amaero’s contracts with companies, including Boeing

and Airbus, citing commercial confidentiality. Those contracts are

expected to pay in part for the building of further large format

printers, at a cost of around A$3.5 million ($2.75 million) each, to

ramp up production of jet engine components.

3D printing can cut production times for components from three months to just six days.

Ian

Smith, Monash University’s vice-provost for research, said it was very

different to the melting, molding and carving of the past.
“This

way we can very quickly get a final product, so the advantages of this

technology are, firstly, for rapid prototyping and making a large number

of prototypes quickly,” Smith said. “Secondly, for being able to make

bespoke parts that you wouldn’t be able to with classic engineering

technologies.”

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Australia researchers create 'world's first' 3D-printed jet engines