Hyperganic 3D printed a rocket engine prototype that was designed using an Excel spreadsheet and a novel algorithm. Rocket engines are manufactured from individual parts like those that make up the combustion chamber, for example.
Cooling channels in a rocket engine circulate the fuel to keep it from overheating and are welded to the combustion chamber. This may make replacing parts or improving individual components to the rocket engine assembly more difficult in the traditional product design lifecycle.
In terms of replaceability, printing a rocket engine as one part does not seem like an efficient notion. Hyperganic tasked the rocket scientist with expressing the shape of the rocket engine parts as formulas stored in an Excel spreadsheet.
The resulting model of a rocket engine was able to be printed in different material densities, which is an unusual modality for rocket design. The goal was to reduce weight in areas that could afford it, and the material density ranges from very solid in the middle of the model to more porous near the its exterior. News Sections. Manufacturing News. Metal Additive Manufacturing News. Recent 3D Printing Research. Latest AM Corporate News. Company and Product News. NetFabb News.
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MeshMixer News. Simplify3D News. Thingiverse News. Apr Image courtesy of Hyperganic. Leave a comment.My thanks to the University of Canterbury for supporting some of these projects. The blood supply to his flipper was blocked and it had to be amputated. The staff at the Christchurch Antarctic Centre came to the rescue and cared for affectionately named Bagpipes. The University of Canterbury was asked to 3D Print him a prosthetic. Stirling Engines are unique due to their ability to operate using heat energy from just a cup of hot water.
This low temperature is within the capabilities of standard 3D printing materials so fully working engines can be 3D printed. See here. The engine shown above is believed to be the first fully 3D printed working engine. View it running here. In New Zealand, to give someone a chocolate fish is to give someone a reward for being spectacular.
The aim of this project was to 3D scan a sculptured model of an indigenous fish and create a scaled down 3D printed plug for vacuum forming a chocolate mould. Vacuum thermo forming is a fun way of making thin wall plastic parts. Using a simple 3D printed vacuum forming chamber, a vacuum cleaner, a stove and your custom 3D printed plug mould you can let your imagination run wild and make all sorts of moulds for chocolate, plaster parts and silicon rubber or model car bodies etc.
Skip to content. This website is dedicated to sharing some of the projects many talented people and I have worked on in the hope that you will find them interesting and informative. It is a living site so content will be added when time permits. All downloadable content is free. Don Clucas My thanks to the University of Canterbury for supporting some of these projects. Learn More. To learn more about these engines and find files for making your own engines click below….
Go to Engines Page. Making Chocolate Fish In New Zealand, to give someone a chocolate fish is to give someone a reward for being spectacular. Discover More.
This setup does not require an expensive vacuum pump or radiant heater. The vacuum forming thermo forming setup. Vacuum formed part and the plug mould.Engine Toyota 22re + 5 speed and 4x4 offroad transmission full 3d printed
More To Come.The last time engineers designed a civilian turboprop engine from scratch for mass-production, humans had not yet landed on the moon. Unlike jet engines, turboprops typically power small commercial shuttles and personal aircraft, but they still represent a multibillion-dollar market.
As a result, a new machine created by a team at GE Aviation is now causing a stir. The designers reduced separate parts down to just As a result, more than a third of the engine is 3D-printed. Engineers working on the ATP are planning to run it for the first time in a special test cell in Prague, Czech Republiclater this year.
It should see its first test flight in lateand full production is expected to begin in Additive manufacturing has helped the GE team bring the ATP from an idea to a working machine in record time. The normal cycle to get to a running engine is usually twice as long, and it can take as much as 10 years to develop, Follin says.
Image credit: Textron Aviation. The engine is 5 percent lighter, which means it will take the aircraft less fuel to attain the same speed. Design changes will allow the ATP to burn 20 percent less fuel and achieve 10 percent more power than its competitors. The engine is expected to run 1, hours longer between overhauls compared to its competitors. They are now putting them together, adding instrumentation and getting ready to test critical sub-units.
Additive manufacturing also simplifies the supply chain and lowers the opportunities for delays. It lets us disrupt the process. Last year, the company acquired two manufacturers of 3D-printing machines and launched GE Additivea new GE business dedicated to supplying 3D printers, materials and engineering consulting services.
Additive manufacturing makes products stronger and more durable. In production aircraft engines, those investments have started paying dividends. Follow Us.German software company Hyperganic has developed a 3D-printed rocket engine prototype, which was completely designed by artificial intelligence.
Unlike a traditional rocket engine, which consists of individually designed parts that are combined together, the AI-designed demonstrator is 3D printed as one continuous piece. This includes both the combustion chamber where fuel and oxidiser is burned and the surface channels, through which the fuel is circulated to cool the chamber and keep it from overheating.
To create the engine, a rocket scientist first stipulated the core features of a rocket engine — the shape of the combustion chamber and the necessary cooling performance. Rather than being translated into CAD files, this information is expressed as formulas and stored in an Excel sheet, in a format that can be read by Hyperganic's algorithm.
This algorithm then uses the data to generate the geometry of the final piece from the bottom up. So the process doesn't create a blueprint, but the DNA for an object. From there, the information is fed to an industrial 3D printer, which realises it using an aerospace nickel alloy called Inconel Every extra pound counts. Hyperganic is currently in talks with different space companies about how this approach could be integrated into their design process.
If the process is implemented by an aerospace organisation, the design will be further refined using a digital evolution feedback loop. The new models are always generated from scratch. Every time you change your requirements, you get another rocket that is perfectly designed for the needs that you've set out. Beyond rocket engines, the company's AI-driven software platform also lends itself to an almost infinite range of other products.
But a component like the cooling channels is very similar to our blood vessels so you could take these components from the rocket and design another solution for creating a synthetic organ for example.
In the US, dedicated aerospace manufacturer Relativity Space has developed a 3D-printed rocket that is built using autonomous robots and has one percent as many individual parts as a traditional rocket.
While designer Sebastian Errazuriz has argued that the rise of AI-driven design would put architects out of businessHyperganic argues that its method is still dependant on human-input with the AI simply doing the heavy lifting.
Last year, a patent application filed for AI-designed products was denied by the European Patent Office, stating that the inventor designated in the application has to be a human being. Dezeen Weekly is a curated newsletter that is sent every Thursday, containing highlights from Dezeen. Dezeen Weekly subscribers will also receive occasional updates about events, competitions and breaking news. We will only use your email address to send you the newsletters you have requested. We will never give your details to anyone else without your consent.
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Subscribe to our newsletters. Dezeen Daily Dezeen Weekly. Thank you! You will shortly receive a welcome email so please check your inbox. You can unsubscribe at any time by clicking the link at the bottom of every newsletter.It was used in the Corvette for 5 years from to and in the Camaro SS for another 5 years from to The LS3 is an updated version of the LS2 casting, but with bigger bores and a The sound is raw and distinct, as the pistons fire at offset intervals, which rattles the block a lot more.
The project was exciting, time consuming, but in the end, totally worth it. These next few blogs will be a part-by-part account of the entire project from start to finish. However, I knew that modelling an engine assembly from scratch was going to take an unreasonable amount of time. You can find all of his designs on Thingiverse. The parts are extremely detailed have been designed for easy fastening, with pre-cut holes and bores for M3-sized screws.
The entire engine — once assembled — moves freely, with integrated bearing sockets for the crankshaft and camshaft. A DC motor is attached to a mounting point that connects the motor to the flywheel, meaning the entire thing will run on its own once powered.
I wanted to demonstrate something a little more dynamic, so I planned out a design for a gas pedal which I will discuss in a later post. The pedal would act as a potentiometer that would regulate the speed of the pistons.
GE’s 3D-Printed Airplane Engine Will Run This Year
Printing all of these parts was a lot of fun. I had three printers at my disposal, the Fortus mc, the mcand the Stratasys F, part of the Stratasys F Series. These three printers, though different in both age and capability, extruded the parts in incredible detail with no hiccups or setbacks.
I had more colour choices for the mc such as orange, yellow, and greyso I used it a lot more than I did the F and mc. I tried to stick with a double-density sparse infill for most of the parts, as it was good balance between material efficiency and part strength.
Pistons, piston rods, and camshaft assembly all printed on one build sheet. This optimisation was implemented with every printed cluster of parts. Next was the engine block. This was the longest print out of all of the parts. The block was done on the MC and took almost 4 days to finish not including time for washing and drying.
I wanted to print the block in orange harking back to classic orange Chevy V8 enginesand the only orange material I had was for the Printing and washing the engine block took almost 6 days to complete. These parts included the headers, intake manifold, cylinder heads, crankshaft, and flywheel.
A few bracket parts like the valley plate and covers were printed in grey to accent the black and orange. Smaller parts, such as the crankshaft assembly seen below, needed to be printed at a lower layer thickness in order to maintain part detail and fastening features. This was especially important for gears, as the gear teeth needed to be detailed enough for them to sink in and align properly. The crankshaft assembly was printed on the F at a thickness of.It's one thing to 3D-print something as advanced as a jet engine, but it's another to fuel it up and push the start button.
That's the step that GE Aviation took when it recently fired up a simple jet engine made entirely of 3D-printed parts in a test stand normally reserved for commercial jet power plants. The result of several years' work, the purpose was to test the printing technology. It's not the first 3D-printed jet enginebut it has been fired and revved up to 33, RPM.
DLMM works by laying down a fine metallic powder in a flat layer, then a laser fuses a section of the CAD plan within it. Another layer of dust is laid down and the process is repeated. When the printing is completed, the excess powder is blown and brushed away, and the part is given a finish.
Source: GE Reports. LOG IN. Menu HOME. Search Query Submit Search. Facebook Twitter Flipboard LinkedIn. View 6 Images. Several jet parts being printed Photo: GE Aviation. David Szondy.
David Szondy is a freelance journalist, playwright, and general scribbler based in Seattle, Washington. A retired field archaeologist and university lecturer, he has a background in the history of science, technology, and medicine with a particular emphasis on aerospace, military, and cybernetic subjects.
In addition, he is the author of a number of websites, four award-winning plays, a novel that has thankfully vanished from history, reviews, scholarly works ranging from industrial archaeology to law, and has worked as a feature writer for several international magazines. He has been a New Atlas contributor since Sign in to post a comment.
GE fires up fully 3D-printed jet engine
DavidJ61 May 14, AM. I could see titanium printing taking over on large blade molding. Large printers could probably save a lot of time and money over the current process for a singular titanium blade and would I guess offer similar performance without needing to add the nubs midway up the blade to use cheaper materials. Definitely excited to see how it all plays out. Raf May 14, AM.
Would be nice to know the specs. Expanded Viewpoint May 14, PM. Effen A man!Remember the guy we featured a few months ago who 3D printed a functional scale model of a Subaru EJ20 flat-four? Well, he's got another creation, and this one's even better. It's a replica of the LS3 V8 found in the last-gen Chevrolet Camaro, and aside from a few fasteners and bearings, it's entirely 3D printed. Harrell says it took hours to print all the parts, including 72 hours just for the engine block.
If you want, you can download all the files to 3D print an LS3 yourself, and Harrell will sell you all the extra hardware to make it work. If you don't have a 3D printer, he'll even send you a complete engine replica. What's especially great is watching Harrell's build timelapse.
It comes together exactly like a full-sized LS3, and when it's done, an electric "starter" motor makes it spin like one too. Type keyword s to search.
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