The Indian manufacturer Fabheads has demonstrated in a recent application how continuous fiber-reinforced 3D printing can be used in aerospace engineering to efficiently produce functional lightweight structures. Specifically, the project involved the production of a structural component for an unmanned aerial vehicle (UAV) that needed to withstand high mechanical loads while keeping weight to a minimum. Traditional metal components proved too heavy, while conventional composite manufacturing methods did not meet the project’s requirements in terms of cost and production time.
Using Fabheads’ proprietary additive manufacturing technology, which is based on the integration of continuous carbon fibers into a polymer matrix system, the team was able to produce a part that, according to the company, is approximately 60 percent lighter than an equivalent aluminum component. At the same time, its mechanical strength was reportedly increased threefold compared to traditionally laminated composite materials. Additive manufacturing also enabled a 40 percent reduction in production time, which is particularly advantageous in iterative development processes such as UAV prototyping.
According to the client, the component was successfully integrated into the UAV. The weight reduction led to increased flight endurance, while the enhanced structural strength improved performance in demanding environmental conditions. Economically, the solution also proved viable, as repeatable, automated processes helped reduce production costs.
Fabheads focuses on applications in aerospace, defense, and automotive sectors. The combination of fiber-reinforced printing technology and material-optimized design allows for the production of load-bearing components with a high strength-to-weight ratio—an increasingly important factor in additive manufacturing for function-critical applications.
Metal Binder Jetting: The Key to Efficient Tool Manufacturing? - Exclusive Insights from INDO-MIM
Fill out the form and get instant access to an exclusive webinar on HP's Metal Binder Jetting 3D printing technology with exciting insights from INDO-MIM.Subscribe to our Newsletter
3DPresso is a weekly newsletter that links to the most exciting global stories from the 3D printing and additive manufacturing industry.
