Cranfield University 3D Prints 6-Metre-Long Aluminium Spar

Researchers at Cranfield University in the UK believe to have created the biggest metal part ever 3D printed in one piece. The six-metre- long and 300 kg heavy spar was created using Cranfield’s Wire + Arc Additive Manufacture (WAAM) process.

The research team used the university’s 10-metre metal 3D printer, that has already been upgraded to also produce titanium parts on top of aluminium and steel components. WAAM combines an electric arc as heat source with wire as feedstock and has been already been investigated since the 1990s. The machine uses standard welding equipment, including a welding power source, torches and wire feeding systems, with motion provided by robotic systems or computer numerical controlled gantries.

The double-sided spar was designed by MSc students in order to test the capability of the new WAAM 3D printer and to assess the challenges of building a large structure along with all necessary steps in the production of real aerospace components of similar size. According to the research team, the WAAM technology could enable cost savings of up to 70% compared to traditional manufacturing. Moreover it reduces lead time from well over a year to just a few weeks.

Professor Stewart Williams, Head of Cranfield’s Additive Manufacture programme, said: “Hundreds of millions of pounds are spent on medium to large-scale components by the aerospace industry each year. There is great potential for significant cost savings in terms of waste and production efficiency if we can transform the way these parts are manufactured.” He adds: “This demonstration clearly shows the potential of the WAAM process with this newly-acquired machine for changing future manufacturing processes.”

The University leads the WAAMMat consortium, which comprises 20 industry partners and 13 further universities, targeting the maturation and commercial exploitation of the WAAM process.

Recent research has proved the possibility of achieving even better mechanical properties compared to the equivalent wrought alloys, and the team is supporting the qualification programmes of large aerospace original equipment manufacturers to enable a more sustainable future for aviation.