Airtech and Alpha Additive Manufacture a 1360-Kilo LFAM Structure
An industrial alliance between Airtech Advanced Materials Group and Alpha Additive Technologies has resulted in the creation of a massive component using additive manufacturing. This project marks a milestone in the production of large, ready-to-use parts. 🏗️
The Dimensions of a Colossal Project
The manufactured component is intended for a material handling system and its measurements are impressive: it has a length of 2.4 meters and a final weight of 1360 kilograms. This achievement underscores the capability of LFAM (Large Format Additive Manufacturing) technology to build large-scale functional parts, eliminating the need to assemble multiple smaller pieces.
Key Manufacturing Details:- Technology Used: Polymer extrusion printing (LFAM) that deposits material layer by layer.
- Material: Carbon fiber-reinforced nylon composite, supplied by Airtech.
- Equipment: Alpha Additive printer with a build volume of 3x3x1.5 meters.
Manufacturing a part of this size makes print time a critical factor; one could almost plan a vacation while the machine works.
Overcoming Engineering Challenges
The main challenge was not just printing, but ensuring that structural integrity and dimensional accuracy were maintained throughout the process. The print exceeded 100 continuous hours, followed by a critical cooling phase. The choice of composite material was key to achieving an optimal strength-to-weight ratio.
Keys to Successful Collaboration:- Combined Expertise: Airtech provided its knowledge in advanced materials, while Alpha Additive contributed its large-format printing technology.
- Focus on Results: The goal was to produce a monolithic and functional structure, not just a technical demonstration.
- Process Management: Controlling parameters during the long print duration was essential for success.
The Future of Large-Format Manufacturing
This project serves as tangible proof of the potential of LFAM in industrial sectors that require large, strong, and complex components. The collaboration demonstrates how combining materials expertise with specialized printing technology can solve engineering problems that previously seemed limiting. The ability to produce parts of