Ongoing sustainment for aging aircraft components

The U.S. Air Force increasingly faces sustainment challenges, including cost, speed, and supply chain agility, when using traditional manufacturing methods to maintain aging aircraft components. The department often seeks innovative engineering solutions to keep aircraft aloft and to modernize the fleet. In 2020, they hosted an open competition to quickly find new and creative 3D printing solutions for the C3175 family of hydraulic line clamps. Thousands of these clamps are used in the Air Force’s F-16 aircraft, in areas like landing gear cavities, and they frequently fail after extended exposure to vibration, environmental chemicals, and heat cycling. Historically, these clamps have been injection molded or CNC machined from a phenolic material that off-gases toxic formaldehyde.

InterPRO Helps Distek Serve More Customers with 3D Printed Adapters

InterPRO Additive Manufacturing Group, a service bureau, started as a 3D printing prototyping company and is seeing growth in production applications due to advancements in 3D print technology and materials. InterPRO’s client Distek, a leading manufacturer of laboratory testing instruments for the pharmaceutical and biotechnology industries, asked InterPRO to help them manufacture a motor adapter that would allow prospective customers to use Distek’s technology with customers’ existing motors. InterPRO used Stratasys’ Origin^® One’s next-generation 3D printing hardware and software to print parts compatible with Distek’s bioreactor and their client’s devices. The parts had injection molded-like strength, consistency, and durability. The surface finish had an impressive, consumer-grade look and feel.

Distek’s challenge was to produce a motor adapter compatible with their proprietary bioreactor and their clients’ motors. However, the adapter design wasn’t easily manufacturable by CNC machining, injection molding, or even cast urethane. In addition, the company needed a fast turnaround to meet immediate customer needs for various adapter sizes in low volumes. High up-front tooling costs, long lead times, and low-volume demand ruled out traditional methods. As a result, InterPRO turned to 3D printing as a possible solution.

HDT60 High Toughness Photoplastic
Matte Black, White, Clear

LOCTITE 3D 3843 is a semi-flexible resin with moderate temperature resistance HDT60, high impact strength, and versatility for various applications.

LOCTITE 3D 3843 is a high-strength engineering plastic with good impact resistance and surface finish. It is ideal for many different tooling applications on the production floor.

LOCTITE 3D 3843 displays high green strength and HDT enabling it to print accurately and function at room temperature. It is compatible with a broad range of DLP machines.

Benefits:

Ideal for:

HDT80 High Modulus Photo plastic
Black

LOCTITE 3D IND403 is a high-temperature resistance material that allows the production of parts with high surface quality and outstanding dimensional accuracy. It is ideal for tooling production for processes such as silicone casting, low-pressure molding, and open-mold PU molding. The material can withstand mechanical stresses while maintaining dimensional stability for multiple cycles for fast product development and rapid process iteration.

Benefits:

• High heat deflection temperature, HDT 80^oC
• Tough with good dimensional stability
• Good surface finish

Ideal for:

• Tooling and molds
• Interior applications in automotive