CDME uses ColdMetalFusion metal Additive Manufacturing for obsolete aircraft parts
November 28, 2024
The Ohio State University’s Center for Design and Manufacturing Excellence (CDME), Columbus, Ohio, USA, is working with collaborators to use a ColdMetalFusion to efficiently build one-of-a-kind replacement parts for aircraft.
“We are looking to demonstrate that the use of this technique can significantly improve the speed, flexibility, cost and performance of the component supply chain, enhancing the readiness and effectiveness of the U.S. Air Force,” said Michael Lander, CDME additive lead engineer.
Created by Headmade Materials GmbH, based in Wuerzburg, Germany, ColdMetalFusion builds parts layer-by-layer at a lower temperature and cost than other metal additive techniques. Most Additive Manufacturing processes require support structures to build unique parts to account for internal pressure and gravity, but ColdMetalFusion does not. Parts can be built supportless, allowing for faster repair times and increased cost savings, which could help the US Air Force and other military branches boost their fleet readiness and sustainability.
The project is a collaboration between CDME’s Additive Manufacturing Division, the Tinker Air Force Base Reverse Engineering and Critical Tooling (REACT) Lab team, Additive Manufacturing machine manufacturer EOS, industry partner Headmade Materials and America Makes.
CDME is researching the mechanical properties of the metal material and aims to demonstrate that this emerging technology is reportedly suitable for the US Air Force to expand the lifespan of aircraft. The centre is reportedly now the first academic lab in the United States to use the ColdMetalFusion technique to build metal parts.
“It’s a fascinating process,” said Kaleb Duarte, CDME undergraduate research assistant. “I’m excited to see how Cold Metal Fusion makes metal 3D printing a more accessible and sustainable process across industries.”
The EOS P110, traditionally a polymer Additive Manufacturing machine, is used as is to manufacture metal parts utilising Headmade Materials ColdMetalFusion feedstock material. America Makes is also supporting the project.
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