ATKINS – Additive Manufacturing for Reduced Lifecycle Energy Use

The aim of Atkins is to fundamentally migrate the design, manufacturing and distribution of goods and components away from the high energy-intensive methodologies that we use today to a more sustainable method of production, service and distribution to the consumer. This low-carbon design, manufacturing and service philosophy will be enabled by the unique characteristics of Rapid Manufacturing (RM).  This project has been a collaboration of companies, led by the University of Loughborough in the United Kingdom, with support of the UK Government's Technology Strategy Board.  Boeing's focus on the project has been to identify potential part candidates, support the design optimization for RM and perform the material, structural and business case analysis needed to implement this new technology.  In this presentation, detailed information will be provided on the microstructural and mechanical performance of Ti-6Al-4V materials produced by RM, including static strength, fracture toughness, fatigue life and crack growth resistance.  A case study will also be presented where a candidate part was selected, produced by RM and tested in fatigue to validate coupon data.  It was found that while RM can be used to reduce manufacturing energy utilization and lifecycle energy consumption by reducing part weight, mechanical performance, particularly in fatigue, and overall manufacturing cost are still barriers for commercial aerospace implementation.