Potentials - July/August 2016 - 21

built as prototypes, after which a
small quantity is produced for deployment. Prototypes are usually subjected to countless testing and revisions
to improve the design. Therefore,
many companies fabricate UAVs by
AM in the interest of production time.
UAVs are also gaining traction in the
hobbyist industry. An increased number of hobbyists are fabricating their
own UAVs and are turning to AM as
the fabrication method to acquire
their prototypes at a cheaper cost.
UAVs, such as quadcopters, usually have propellers outside of their
bodies. This design increases the
risk of propeller damage. To mitigate
this design flaw, AM can be utilized
to fabricate propellers inside the UAV
body, which will help to lengthen the
lifespan of the UAV. In addition, AM
can also reduce the weight of the
parts required in a UAV. Components can now be printed as one
hollow piece, or with internal lattice structure, giving it lightweight
and high-strength properties to provide for longer f light time and hi gher payloads.

Potential challenges
of AM in aerospace
AM development for aerospace has
been sluggish due to the need for
the certification and qualification of
parts before they can be implemented for commercial use. Although AM
can provide many benefits to the
aerospace industry, the risk that
comes with its implementation must
be mitigated. There are many variables to be considered, and, unlike
conventional manufacturing, the
lack of understanding and knowledge on effects on AM processes and
alloys raise concerns.
One area of interest, due to the
harsh environment to which an
aircraft is subjected, is the understanding of fatigue and aging in AM
alloys. Parts that are used in aircraft today have undergone extensive testing and certifications to ensure that a certain confidence level
is met. In contrast, due to insufficient information regarding how
AM-produced parts will perform,
especially on their mode of failure,

they are not suited for use as loadbearing structures in an aircraft.
Currently, most AM-printed parts
in the aerospace industry are usually restricted to nonstructural and
noncritical use.

aM in the automotive industry
In the automotive industry, AM has
opened doors for lighter, safer, and
environmentally friendly cars with
shorter production lead times at
reduced costs. AM is also used in the
reproduction of hard-to-find parts.
The main aim in the design of automobiles is to minimize the weight of
the car while ensuring safety. By employing AM techniques, the production of intricate cross-sectional areas,
such as the honeycomb cell or cavities in the parts, is made possible.

Influences on the
automotive industry
AM has an influential contribution in
achieving competitiveness among
automakers. Compared to conventional manufacturing processes that
often restrict design, AM can produce
parts with a higher degree of design
freedom. This versatility is significantly beneficial in the production of
custom features, allowing for the
addition of enhanced functionalities.
For instance, integrated electrical
wiring and reduced weight can be
achieved through the use of hollow
and lattice structures, respectively.
Moreover, novel AM technology has
made the production of multimaterial-printed parts with independent
properties including electrical conductivity and variable strength possible. All these AM processes have
taken on a crucial role in the creation
of lighter, faster, safer and more efficient cars for the future.
In addition, AM is a driver in the
transformation of the supply chain.
Currently, original equipment manufacturers (OEMs) have to collaborate with thousands of suppliers to
source for the different components
in cars, which often result in long
lead time. As supply chain management is an intensive planning and
logistics exercise that is both time
and cost consuming, OEMs are con-

tinually seeking ways to compact
their supply chains. AM has the potential to reduce the costs of moving and distributing mid-process
and end-usable components, as
these components can be produced
on-demand, thereby reducing the
overall lead-time and shortening the
automotive supply chain.
With the various advantages of AM,
companies are able to propel significant change within the supply chain.
These changes include a decrease in
costs and the simplification of the
supply chain. Moreover, the combination of product innovation and transformation of the supply chain will influence the modification of business
models of automobile corporations.

Applications in automotive
Currently, cooling vents and dashboards made by AM technology have
already been adopted in some vehicles. With continuous improvements
in AM processes and materials technology, it is likely that AM-based produced parts will be widely used in
automobiles in the near future. Future
applications may include engine components and suspension springs.
AM has also been used as the primary production technology for the
manufacturing of electric cars. For example, a team of U.S. engineers manufactured URBEE-2 with approximately
50 AM-fabricated components.

Potential challenges of AM in
the automotive industry
Although substantial advantages are
offered by AM, several challenges
have to be taken into consideration.
Low volume production of AM-produced car components is not economical, as profitability is volume driven.
Approximately 86 million automobiles
were manufactured globally in 2013.
With the immense volume, the low
production speed of AM is hindering
its entrance to the direct part-manufacturing market. Research on highspeed AM is therefore essential.
The production of large A Mbased components has proven to be
demanding. Parts like body panels
that are produced by AM processes
will still have to be joined together

IEEE PotEntIals

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