The First Use Of 3D-printed Structural Sintered Titanium Component On A Commercial Aircraft

In a significant milestone for both the aerospace industry and additive manufacturing, the Federal Aviation Administration (FAA) has approved the use of sintered titanium parts manufactured using Norsk Titanium's Rapid Plasma Deposition (RPD) process for Boeing 787 Dreamliner aircraft. The approval marks the first time a 3D-printed structural titanium component has been approved for use on a commercial aircraft.

Norsk Titanium, a U.S.-based supplier of 3D-printed structural titanium components for the aerospace industry, developed the RPD process as a more efficient and cost-effective method for producing titanium parts. The process uses a plasma arc to fuse titanium wire feedstock into near-net shape parts, which are then machined to their final form. The RPD process has a number of advantages over traditional manufacturing methods, including reduced material waste, lower production costs, and faster lead times.

Boeing has been working with Norsk Titanium to evaluate the RPD process for the production of titanium parts since 2015. The companies have been focusing on developing a solution that meets the high standards for safety and quality required in the aerospace industry.

The approval by the FAA is a significant achievement for Norsk Titanium and the wider additive manufacturing industry. It represents a major step forward in the acceptance of 3D printing as a viable production method for aerospace components. The use of sintered titanium parts in commercial aircraft has the potential to significantly reduce the weight and improve the fuel efficiency of these aircraft.

The RPD process has been demonstrated to be effective in producing large-scale titanium parts. The process is particularly well-suited for the production of complex shapes that would be difficult or impossible to produce using traditional machining methods. The use of 3D printing for titanium parts could also help to reduce the lead times and costs associated with the production of these parts.

The approval by the FAA was based on a rigorous testing and certification process. The parts were subject to a battery of tests, including tensile, fatigue, and impact testing, to ensure that they meet the same high standards for safety and quality as conventionally produced parts. The FAA's approval is a testament to the quality of Norsk Titanium's manufacturing processes and the strength of the sintered titanium parts produced using the RPD process.

The use of sintered titanium parts in commercial aircraft is expected to grow in the coming years. The aerospace industry is constantly seeking ways to reduce the weight of aircraft and improve their fuel efficiency, and the use of titanium parts is seen as a key strategy in achieving these goals. The approval of the RPD process by the FAA is likely to spur further investment in additive manufacturing technology by the aerospace industry.

In addition to the aerospace industry, the use of sintered titanium parts has potential applications in other industries as well. For example, the medical industry is increasingly using titanium implants for various procedures, and the RPD process could be used to produce these implants in a more efficient and cost-effective manner.