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ORNL and Boeing Achieve Guinness World Record for Largest Solid 3D Printed Part

Researchers at the Oak Ridge National Laboratory (ORNL) have collaborated with The Boeing Company to 3D print a trim-and-trill tool, which has now received the title of largest solid 3D printed item by Guinness World Records.

ORNL printed the tool in 30 hours using carbon fibre and ABS composite materials. The tool measuring 17.5 x 5.5 x 1.5 feet (5.3 x 1.7 x 0.5 meters) and weighing 1,650 pounds (approx. 748 kg) will be tested in building the Boeing  777X passenger jet. It was 3D printed on the lab’s Big Area Additive Manufacturing machine.

Leo Christodoulou, director of structures and materials at Boeing said: “The existing, more expensive metallic tooling option we currently use comes from a supplier and typically takes three months to manufacture using conventional techniques. Additively manufactured tools, such as the 777X wing trim tool, will save energy, time, labor and production cost and are part of our overall strategy to apply 3D printing technology in key production areas.”

In order to receive the title by Guinness World Records, the component had to exceed the minimum of 0.3 cubic meters.

“The recognition by GUINNESS WORLD RECORDS draws attention to the advances we’re making in large-scale additive manufacturing composites research,” said Vlastimil Kunc, leader of ORNL’s polymer materials development team. “Using 3D printing, we could design the tool with less material and without compromising its function.”

Boeing plans to use the trim-and-drill tool to secure the jet’s composite wing skin for drilling and machining before assembly in their new production facility in St. Louis. Once implemented, feedback on its performance will be reported back to ORNL.

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