Researchers at Raytheon Missile Systems say they have already created nearly every component of a guided weapon using additive manufacturing, more commonly known as 3-D printing. The components include rocket engines, fins, parts for the guidance and control systems, and more.
“You could potentially have these in the field,” said Jeremy Danforth, a Raytheon engineer who has printed working rocket motors. “Machines making machines. The user could [print on demand]. That’s the vision.”
The progress is part of a companywide push into additive manufacturing and 3-D printing, including projects meant to supplement traditional manufacturing processes. Engineers are exploring the use of 3-D printing to lay down conductive materials for electrical circuits, create housings for the company's revolutionary gallium nitride transmitters, and fabricate fins for guided artillery shells.
The process may reduce costs associated with traditional manufacturing, such as machining of parts. It allows for quick design and rapid changes because engineers only need change the digital model representing the part. As long as they stay within set parameters, they can have new parts in hours instead of weeks.
“You can design internal features that might be impossible to machine,” said Raytheon engineer Travis Mayberry, who is researching future uses of additive manufacturing and 3-D printing. “We’re trying new designs for thermal improvements and lightweight structures, things we couldn’t achieve with any other manufacturing method.”
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| Source: Raytheon |
‘KIOSK’ explores a near future scenario in which digital fabrication is so ubiquitous that we see it appear on our
street corners. With KIOSK the user can ‘appropriate, sample, remix, improve, up/downscale or copy new objects
and 3D-print them on the spot.’ KIOSK operates as a portable 3D copyshop capable of producing a ‘custom made
fix for your broken shoe, materialise an illegal download of Starck’s Juicy Salif orange squeezer that you modified for better performance or quickly print out a present for your sister’s birthday.’ For The Machine Unfold, in collaboration with Indianen, created a new creative digital copy station.
A project commissioned by Z33, House for contemporary art and MU Eindhoven.
With the support of Bits from Bytes and Jo Van Bostraeten.
A collaboration with Indianen.
I also have slight suspicion that someone will want to 3d print bombs on-board of military aircraft. Still, all limitations remain. Why send something very expensive and heavy when you have proven delivery methods? Maybe some tactician is thinking of highly customized munition for very demanding missions with uncertain parameters for high-value targets.
“3D printing of warheads will allow us to have better design control and utilize geometries and patterns that previously could not be produced or manufactured,” James Zunino, a researcher at the Armament Research, Engineering and Design Center (ARDEC) in Picatinny, New Jersey, told Motherboard in an email.
The ability to print parts previously unimaginable using traditional manufacturing methods could radically open up the possibilities when it comes to what a warhead can do. For example, warheads using 3D-printed components could be designed to be more compact in order to pack in additional payloads, sensors, and safety mechanisms. Planning for printed parts in the design process will also allow the army to precisely engineer the blast radius of warheads for maximum effect.
“Warheads could be designed to meet specific mission requirements whether it is to improve safety to meet an Insensitive Munitions requirement, or it could have tailorable effects, better control, and be scalable to achieve desired lethality,” Zunino wrote.
As an organization with a shrinking budget—except when it comes to drones—the army weighs the cost of human life against that of building the instruments of its eventual liquidation. One cross-industry advantage of 3D printing is its cost-effectiveness since it enables the printing of complex structures in one go, instead of the many individual parts that go into it. Missiles are no different.
“3D printing also allows for integrating components together to add capabilities at reduced total life cycle costs,” Zunino explained. “It is expected that 3D printing will reduce life-cycle costs of certain items and make munitions more affordable in the long run through implementation of design for manufacturability, and capitalizing on the add capabilities that 3D printing and additive manufacturing can bring to munitions and warheads.”
The army doesn’t plan on stopping at merely printing warhead components, either. Eventually, they want to print the whole damn thing in one go. “Maybe someday an entire warhead or rocket could be produced as the technology further matures,” Zunino wrote.
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| Source: http://www.itclips.net/2013/02/20/touring-the-labs-at-make-hq-3-2/ |
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| Rytheon STM, source: http://weapons.technology.youngester.com/2011/04/new-warhead-small-tactical-munition.html |
Scientists and engineers at BAE Systems have lifted the lid on some futuristic technologies that could be incorporated in military and civil aircraft of 2040 or even earlier.
Smaller unmanned aircraft -- or UAVs -- are created by super high-tech on-board 3D printers, via Additive Layer Manufacturing and robotic assembly techniques. The 3D printers respond to data fed to them by a remote control room where a human commander decides what should be produced.
The UAVs are best suited to each scenario -- be it a group of wide-winged aircraft for protracted or enduring surveillance -- or rotary-winged UAVs to rescue single civilians or soldiers from dangerous situations. After use the UAVs could render themselves useless through dissolving circuit boards or they might safely land in a recoverable position if re-use was required.
This creates the ultimate adaptable taskforce, with a lead aircraft able to enter any unknown scenario and quickly manufacture an effective toolset for any task.
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| They don't even use real 3d printed models in the videos but plastic toy guns |
"Legal encapsulation is not effectively possible," declares Cody Wilson of Defense Distributed, makers of the world's first gun made via 3D printing technology. "So it's fun to kind of challenge the state to greater and greater levels of its own hyper-statism."
Last year, Wilson and crew unveiled The Liberator, a plastic pistol they created on a 3D printer that fired a shot heard around the world. Then they put the 3D-printing files (or CADs) up on the Internet for free. To folks interested in cutting-edge technology and decentralized experiments in living, Wilson's gun symbolized an age of uncontrollable freedom. To lawmakers, it symbolized a threat that moved faster than, well, a speeding bullet. The State Department, in fact, shut down Defense Distributed's ability to disseminate the gun files on the Internet, claiming the nonprofit was violating federal rules about exporting munitions.
A self-declared crypto-anarchist, the 26-year-old Wilson is fighting the situation in court—and relishing every minute of his battle with the government.Stay safe people ... liberty is responsibility ...
While he's aggressively challenging restrictions on 3D-printed guns, Wilson is also working on an innovative Bitcoin project called Dark Wallet, which would further anonymize financial transactions on the Web, and a book intended to inspire a new generation of digital libertarians.
"Solid Concepts, which last month revealed the first fully-functional, metal 3D gun, announced today that they're putting 100 limited-edition models of the 1911 .45 caliber pistol on sale for $11,900 each. Solid Concept demonstrated the gun by initially firing 50 rounds through it. Since then, the company said it has fired nearly 2,000 rounds through the pistol without a single malfunction. Unlike the very first 3D printed gun — the single-shot, plastic Liberator — Solid Concepts says is not trying to promote the right to bear arms under the Second Amendment. Its purpose in printing the firearm was to demonstrate its ability to turn out precision, durable parts that could withstand the massive pressure created by firing a bullet. People who purchase one of the limited-edition guns will also have the chance to tour Solid Concept's Texas facility to see their gun being printed, and to join their lead additive manufacturing engineers on the range for the first test firing of their limited 1911 gun."Company page:
Solid Concepts, a world leader in 3D Printing services, manufactures the world’s first 3D Printed Metal Gun.
Austin, TX – Solid Concepts, one of the world leaders in 3D Printing services, has manufactured the world’s first 3D Printed Metal Gun using a laser sintering process and powdered metals. The gun, a 1911 classic design, functions beautifully and has already handled 50 rounds of successful firing. It is composed of 33 17-4 Stainless Steel and Inconel 625 components, and decked with a Selective Laser Sintered (SLS) carbon-fiber filled nylon hand grip. The successful production and functionality of the 1911 3D Printed metal gun proves the viability of 3D Printing for commercial applications.
“We’re proving this is possible, the technology is at a place now where we can manufacture a gun with 3D Metal Printing,” says Kent Firestone, Vice President of Additive Manufacturing at Solid Concepts. “And we’re doing this legally. In fact, as far as we know, we’re the only 3D Printing Service Provider with a Federal Firearms License (FFL). Now, if a qualifying customer needs a unique gun part in five days, we can deliver.”
The metal laser sintering process Solid Concepts used to manufacture the 30+ gun components is one of the most accurate additive manufacturing processes available, and more than accurate enough to build the interchangeable and interfacing parts within the 1911 series gun. The gun proves the tight tolerances laser sintering can meet. Plus, 3D Printed Metal has less porosity issues than an investment cast part and better complexities than a machined part. The 3D Printed gun barrel sees chamber pressures above 20,000 psi every time it is fired. Solid Concepts chose to build the 1911 because the design is public domain.
“The whole concept of using a laser sintering process to 3D Print a metal gun revolves around proving the reliability, accuracy and usability of metal 3D Printing as functional prototypes and end use products,” says Firestone. “It’s a common misconception that 3D Printing isn’t accurate or strong enough, and we’re working to change people’s perspective.”
The 3D Printed metal gun proves that 3D Printing isn’t just making trinkets and Yoda heads. The gun manufactured by Solid Concepts debunks the idea that 3D Printing isn’t a viable solution or isn’t ready for mainstream manufacturing. With the right materials and a company that knows how to best program and maintain their machines, 3D printing is accurate, powerful and here to stay.
According to the court’s spokeswoman Ilse Westenenk, the courtroom regularly works together with the college. ‘That’s why we gave them permission, but obviously after checking they were actual Avans students,’ she said.
The spokeswoman further revealed that the court was already aware of these loopholes in the security system, but added that this experiment will not lead to a tightening of security.
‘We have known for some time that knives of this kind cannot be detected by metal scanners. 3D printed weapons simply require other security measures. But for now we will uphold the current balance between security and transparency,’ she said. The courtroom and its corridors are also patrolled by security personnel.
