3D Printed Replacement Part for an F-16 Aircraft: The Cool Parts Show #54

Sustainment - the ongoing maintenance and repair of existing equipment, including replacing worn or damaged parts - represents a major opportunity for 3D printing in military operations. The U.S. Air Force explored what it would take to not only 3D print but validate a replacement part through its Approval Sprints Challenge, a contest held as part of its Advanced Manufacturing Olympics in 2020. Teams were tasked with developing and 3D printing a clamp that holds two hydraulic lines in an F-16 aircraft. The winning entry seen in this episode was developed by Stress Engineering, Origin and nTopology. Despite a dramatic setback, this clamp prevailed due to its innovative material choice and human-centered design, along with a qualification strategy that could be applied to many more replacement parts in the future.
This episode of The Cool Parts Show brought to you by Carpenter Additive. www.carpenteradditive.com/
LEARN MORE ABOUT:
- The Advanced Manufacturing Olympics www.additivemanufacturing.med...
- How Stress Engineering assisted with a much larger replacement part, 3 feet long and weighing more than 500 pounds www.additivemanufacturing.med...
- How Origin’s materials-focused development informs its 3D printer technology www.additivemanufacturing.med...
- More on the distinctive characteristics of Origin’s DLP process www.additivemanufacturing.med...
- Another Cool Part optimized with nTopology www.additivemanufacturing.med...
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[@AdditiveManufacturing]

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[@RuslanKagirov]

Plastics are very sensitive to temperature changes, so material parameters are key in such details.

[@matbeedotcom]

You two are destined to be featured in some college courses with a wheeled-in TV

[@TheTTAM31]

I love The Cool Parts Show!

[@jmd1743]

3d printed parts like that opens the door to more legacy replacement parts being manufactured. Maybe equipment will be used longer because the military isn't beholden to the OEM's will. Maybe not a whole engine but how about landing gear parts or a radar bracket or translucent landing light covers? Little things like that add up to the viability of platforms.

[@BisdremisKostas]

How would feel knowing that this thing cracks if over torqued?

[@abcqer555]

Great video. Funny how they tested every detail under simulation but didn't account for an unknown variable as simple as over torquing it. Did they adjust their design to account for that? Fantastic work by the team and love the qualification loop they designed

[@MarkLawry]

The way I heard it, they DID account for over torquing by providing torque specifications. The problem was that the installer did not follow them. Applying proper torque at installation is fundamental for any mechanic. Especially an aircraft mechanic. And even more so, a mechanic for the Air Force.

[@sl_st]

Very interesting stuff. I am concerned about the following question. Why not make clips? In the sense of locks on the ends of the attachment? To prevent this clamp from opening? So you can make the part even lighter and stronger, relative to the load.

[@AdditiveManufacturing]

From Matt Sanders: "Clips were considered during the design iteration process. In the end, that design concept was eliminated because it was found they were not necessary to achieve the needed strength and would increase the weight and installation complexity."

[@sl_st]

@@AdditiveManufacturing Of course, I understood that you were interrupting a lot of options :) I just wanted to know why this one was dropped. Can I try to make my own variations and put them on GrabCAD? I will be glad if you take a look later;)

[@AdditiveManufacturing]

Sure! Come back and share the link(s).

[@sl_st]

@@AdditiveManufacturing GrabCAD SL_ST PIPE LINE CLAMP

[@AdditiveManufacturing]

Nice work! We didn’t discuss it directly in the episode, but this design reminds us a little of the variation of the clamp visible around 5:36.

[@polyfoamcoats1650]

16:10 It ended up cracking? So it wasn't good after all...

[@AdditiveManufacturing]

The part cracked because of over-torquing during installation, rather than any direct result of the design or material. As we understand it, the properly installed clamp would be a perfectly viable replacement.

[@FilmFactry]

Government loves to waste money. What did this cost? I guarantee in the 60s they did none of this and they used that part for 50-60 years.

[@rebornfenix4412]

This sounds like marketing told the engineers “do something cool with the automagical printy thingy” and the engineers went “hey, the Air Force wants something cool so now marketing will pay us to bs and do something cool.”