Boeing revealed a 3D-printed main rotor link assembly for an AH-64 Apache helicopter during the AUSA Annual Meeting & Exposition, DefenseNewsreported.
According to Boeing Global Services additive manufacturing engineer Andy Pfeiffer, Boeing intends to 3D print components related to the main rotor system and perform fatigue testing against forged parts next spring.
Boeing officials explained that the project aims to reduce lead times and optimize supply chains, particularly for components that are commonly forged.
3D printing the main rotor link assembly took eight hours while depositing the 6,000 series aluminum required 45 minutes. Pfeiffer commented that the lead time for forging this part takes one year.
The 3D-printed main rotor system results from a collaboration between Boeing and ASTRO America, a U.S. government-funded nonprofit. The U.S. Army’s Ground Vehicle Systems Center recently awarded ASTRO a $95 million contract for engineering assistance to enhance additive manufacturing.
The Apache program has identified eight parts in need of replacement that were recognized as viable options for 3D printing.
However, according to Boeing welding engineer Scott Rose, choosing between forging and 3D printing parts depends on the quantity of the components: large production volumes favor forging, and smaller amounts lean toward 3D printing.
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Image Credit: Tech. Sgt. Matt Hecht/U.S. Defense Department
