A 3-D printed trim-and-drill tool, developed by ORNL researchers and to be evaluated at The Boeing Company, has received the title of largest solid 3-Dprinted item by Guinness World Records.
ORNL printed the lower cost trim tool in only 30 hours using carbon fiber and thermoplastic composite materials, which will be tested in building the Boeing 777X passenger jet. At 17.5 feet long, 5.5 feet wide and 1.5 feet tall, the 3-D-printed structure is comparable in length to a large sport utility vehicle and weighs approximately 1,650 pounds.
鈥淭he existing, more expensive metallic tooling option we currently use comes from a supplier and typically takes three months to manufacture using conventional techniques,鈥� said Leo Christodoulou, Boeing鈥檚 director of structures and materials. 鈥淎dditively manufactured tools, such as the 777X wing trim tool, will save energy, time, labor and production cost and are part of our overall strategy to apply 3-D printing technology in key production areas.鈥�
During an awards ceremony held Aug. 29 at DOE鈥檚 Manufacturing Demonstration Facility at ORNL, where the component was 3-D printed on ORNL鈥檚 Big Area Additive Manufacturing machine, Guinness World Records judge Michael Empric measured the trim tool, proved it exceeded the required minimum of 0.3 cubic meters, or approximately 10.6 cubic feet, and announced the new record title.
manufacturing composites research,鈥� said Vlastimil Kunc, leader of ORNL鈥檚 polymer materials development team. 鈥淯sing 3-D printing, we could design the tool with less material and without compromising its function.鈥�
After ORNL completes verification testing, Boeing plans to use the additively manufactured trim-and-drill tool in the company鈥檚 new production facility in St. Louis and provide information back to ORNL on the tool鈥檚 performance. The tool will be used to secure the jet鈥檚 composite wing skin for drilling and machining before assembly. Production of the 777X is scheduled to begin in 2017 and first delivery is targeted for 2020.
The project is supported by DOE鈥檚 Office of Energy Efficiency and Renewable Energy Advanced Manufacturing Office (AMO), which supports applied research, development and demonstration of new materials and processes for energy efficiency in manufacturing as well as platform technologies for the manufacturing of clean energy products.
More information about ORNL鈥檚 Innovations in Manufacturing program is available at .
After ORNL completes verification testing, Boeing plans to use the additively manufactured trim-and-drill tool in the company鈥檚 new production facility in St. Louis and provide information back to ORNL on the tool鈥檚 performance. The tool will be used to secure the jet鈥檚 composite wing skin for drilling and machining before assembly. Production of the 777X is scheduled to begin in 2017 and first delivery is targeted for 2020.
The project is supported by DOE鈥檚 Office of Energy Efficiency and Renewable Energy Advanced Manufacturing Office (AMO), which supports applied research, development and demonstration of new materials and processes for energy efficiency in manufacturing as well as platform technologies for the manufacturing of clean energy products.
More information about ORNL鈥檚 Innovations in Manufacturing program is available at .
