Partners produce rotor blade 3D-printed tool on Ingersoll 3D printer

The effort utilised Ingersoll’s hybrid large format MasterPrint gantry type 3D printer and 5-axis milling machine housed at Ingersoll’s headquarters facility in Rockford, IL.

“We are continuously testing and advancing MasterPrint in our Development Centre,” said Chip Storie, CEO at Ingersoll. “Among Ingersoll’s short-term objectives is for MasterPrint to 3D-print moulds for aerospace that preserve the geometrical properties and tolerances, vacuum integrity and autoclave resilience normally obtained with traditional technology, but with the cost and time reduction only additive manufacturing can offer. The relentless progress our MasterPrint process has made in 2020 has finally made this target attainable.”

After printing, the mould surfaces and tooling location features were machined to finished dimensions by exchanging the print module for the 5-Axis milling head which is changeable on the MasterPrint machine. The machining was completed in one week and the final part achieved full vacuum tightness. The Ingersoll machine uses the Siemens 840D CNC control system for controlling both the machining and the 3D printing.

Critical time savings was achieved through the 3D print fabrication and efficient 5-axis machining operations. The additive and subtractive manufacturing processes were seamlessly co-engineered in the native CAD software format. The traditional build cycle for a typical mould in aluminium such as this using standard methods is typically 4-5 months. This manufacturing process was completed in a matter of weeks.

“For many years Bell has used composite materials for manufacturing airframe components, including components produced on an Ingersoll Machine Tools Tape Layer machines,” said James Cordell, senior manager, process stability, Bell. “These similar materials are now being utilised for manufacturing the moulds that form the airframe components. Employing this rapid manufacturing equipment will allow Bell. to greatly accelerate our development of tooling for many applications within the Bell organisation.”

Ingersoll Machine Tools has played an important role in enabling breakthrough airframe production techniques for major aircraft designs around the world and we appreciate the opportunity to support Bell in building their future.

https://en.machinetools.camozzi.com/who/ingersoll-machine-tools.kl

www.camozzi.com