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Elon Musk Makes 3-D Printing History
fool.com ^ | June 2, 2014 | Steve Heller

Posted on 06/02/2014 5:43:28 PM PDT by ckilmer

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Elon Musk Makes 3-D Printing History

By Steve Heller | More Articles | Save For Later
June 2, 2014 | Comments (6)

 

SpaceX Dragon V2. Source: SpaceX.

Wearing his hat as CEO of SpaceX, Elon Musk unveiled the future of space transport with the Dragon V2 spacecraft on Friday. Unlike Dragon V1, which was designed to carry cargo loads to and from the International Space Station, Dragon V2 will be able to transport up to seven humans to and from the ISS, and its robust thermal protection system makes the spacecraft capable of lunar missions, paving the way for interplanetary human travel.

Dragon V2 includes significant upgrades never before seen on a human spacecraft, including the addition of eight specially designed SuperDraco rocket engines capable of producing up to 120,000 pounds of combined axial thrust, which can be used during any stage of the ascent to carry astronauts to safety in the event of an emergency and land with helicopter-like precision. As an added benefit, the SuperDraco engines will also eliminate the need for parachutes when reentering earth's gravitational field. Retrieving a spacecraft that landed somewhere in the ocean will become a thing of the past when Dragon V2 it starts shuttling humans to and from the ISS in late 2016.

In an act of true technological achievement, the SuperDraco engines were made entirely with a 3-D printer out of an extremely durable metal superalloy called Inconel and will be the first 3-D printed rocket engine to ever experience flight. Below you'll find the relevant video segment during the Dragon V2 unveil, where Musk talks about the SuperDraco.

 

Source: SpaceX.

A match made in heaven
On a high level, 3-D printing is a layer-by-layer additive manufacturing process that excels at creating complicated designs because it eliminates the need for expensive tooling and its associated waste. The drawback of using a repetitive layer-by-layer manufacturing process is that it's slow as molasses, making it currently impractical for large-scale manufacturing runs. Where 3-D printing really shines is with lower volume, or one-off manufacturing runs where tooling isn't economical and production is limited. The SuperDraco rocket engine, of which only a relatively small amount will be produced, is the perfect application.

Musk believes that "through 3-D printing, robust and high-performing engine parts can be created at a fraction of the cost and time of traditional manufacturing methods"; and added, "SpaceX is pushing the boundaries of what additive manufacturing [3-D printing] can do in the 21st century, ultimately making our vehicles more efficient, reliable and robust than ever before." What Musk is alluding to is how 3-D printing enables the SuperDraco engine to be manufactured as one finished part, which requires no assembly, increases the part's structural integrity, improves its reliability, and lowers the overall cost to manufacture. Building a SuperDraco engine would've been next to impossible using conventional manufacturing methods because Inconel is a very difficult super alloy to machine.

 

The SuperDraco 3-D printed rocket engine. Source: SpaceX.

The 3-D printer behind SuperDraco
Based on Elon Musk's Twitter post from Sept. 5, it's highly likely the unveiled SuperDraco engine was made by an EOS 3-D printer, a privately held German-based 3-D printing company that competes directly with 3D Systems (NYSE: DDD  ) in the 3-D metal printing segment.

EOS is widely regarded for having the most capable and accurate type of 3-D metal printing technology known as direct metal laser sintering, or DMLS, which utilizes a laser to selectively heat and melt medal powder in a layer-by-layer process. For obvious concerns around safety and quality assurance, SpaceX went with the most robust 3-D printing technology on the market and pushed its boundaries.

Plenty of room
With 3-D metal printing growth being as strong as it has been, the market appears to be large enough for 3D Systems and other players to also carve out market share in the segment. Last year, 3D Systems purchased Phenix Systems in an effort to strengthen its 3-D metal offerings against EOS and other competitors in the space. During 3D Systems' first-quarter earnings call, the company highlighted that demand for its 3-D metal printers continued to outstrip supply, despite it recently adding increased manufacturing capacity. 3D Systems' metal 3-D printers have been a significant contributor to its printer orders backlog, which stood at $17.9 million at the close of the first quarter. Going forward, 3D Systems investors should expect the company to introduce a larger format metal 3-D printer by the end of the year that will better appeal to companies like General Electric -- and possibly even SpaceX -- with large manufacturing footprints.

It all starts from the top
As a technology, 3-D printing has often been touted as the foundation for what is referred to as the Third Industrial Revolution, promising to fundamentally change how the world manufactures anything and everything. From SpaceX's 3-D printed rocket engines, to General Electric's 3-D printed jet engine fuel nozzles, 3-D metal printing for real-world manufacturing applications continues to advance at what certainly feels like an incredible pace. Although it will likely take many years until the technology expands beyond the scope of advanced manufacturing applications we're seeing today, companies like SpaceX and General Electric will continue to push the boundaries of 3-D metal printing technology further, which may not only benefit 3-D metal printing suppliers like EOS and 3D Systems, but also society at large.


TOPICS: Business/Economy
KEYWORDS: 3dprinting; elonmusk; spacex

1 posted on 06/02/2014 5:43:28 PM PDT by ckilmer
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To: ckilmer

the pictures connect to videos at the link.


2 posted on 06/02/2014 5:44:01 PM PDT by ckilmer
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To: ckilmer
On a high level, 3-D printing is a layer-by-layer additive manufacturing process that excels at creating complicated designs because it eliminates the need for expensive tooling and its associated waste. The drawback of using a repetitive layer-by-layer manufacturing process is that it's slow as molasses, making it currently impractical for large-scale manufacturing runs. Where 3-D printing really shines is with lower volume, or one-off manufacturing runs where tooling isn't economical and production is limited. The SuperDraco rocket engine, of which only a relatively small amount will be produced, is the perfect application.

Absolutely true. That's why it's called Additive Manufacturing now.

3 posted on 06/02/2014 5:52:31 PM PDT by Regulator
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To: bestintxas; thackney; Kennard

additive manufacturing doesn’t do well for high volume just yet because its slow— but additive manufacturing is very good for short runs—that is manufacturing relatively few pieces of the same thing.

This sort of thing at some point just has to be made for oil the oil business.

You just put one of the 3D printers near a couple sites and make what you need on the spot. The time it would take to train a guy to do the job would be minimal.


4 posted on 06/02/2014 5:52:42 PM PDT by ckilmer
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To: ckilmer

You would need a metal 3-d printer, industrial strength, those can’t be too cheap. Probably fit in a big rig though.


5 posted on 06/02/2014 5:54:25 PM PDT by GeronL (Vote for Conservatives not for Republicans)
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To: ckilmer

bttt


6 posted on 06/02/2014 5:55:11 PM PDT by Dave W
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To: ckilmer
Saturn V had 1.5 million pounds thrust in its second stage.
7 posted on 06/02/2014 5:55:56 PM PDT by Steely Tom (How do you feel about robbing Peter's robot?)
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To: GeronL

They’re not cheap NOW. Ten years ago, computer-driven milling was a quarter mill: you can buy machines now for under a thousand dollars.

Give it time (grin)


8 posted on 06/02/2014 6:16:07 PM PDT by Salgak (http://catalogoftehburningstoopid.blogspot.com 100% all-natural snark !)
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To: Salgak

bump


9 posted on 06/02/2014 6:16:42 PM PDT by GeronL (Vote for Conservatives not for Republicans)
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To: Steely Tom
Saturn V had 1.5 million pounds thrust in its second stage.

Saturn V had to climb out of a MUCH deeper gravity well than just to the ISS LEO.

Still, a magnificent accomplishment, especially since it was 45 years ago!

When we did a tour of the Cape years ago, the guide showed us where the one of the control computers was mounted on an intermediate ring between stages. I asked what the equivalent computing power was.

"Oh, about that of the original IBM PC."

10 posted on 06/02/2014 6:23:46 PM PDT by BwanaNdege ( "For those who have fought for it, Life bears a savor the protected will never know")
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To: Steely Tom
Saturn V had 1.5 million pounds thrust in its second stage.

These rockets are for the little module that gets into orbit, not the heavy first and second stages. All this needs to do is take the small capsule out of orbit, and slow down from terminal velocity to zero.

SpaceX Dragon V2 | Flight Animation

11 posted on 06/02/2014 6:30:22 PM PDT by Vince Ferrer
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To: Salgak
"...computer-driven milling was a quarter mill: you can buy machines now for under a thousand dollars."

Really?? Who from??? (No sarcasm intended.....VERY serious question). I try to follow the small, inexpensive mill market (especially CNC) fairly closely, and haven't found any in that price range (you "can" get a NON-CNC mill in that range).

12 posted on 06/02/2014 6:37:13 PM PDT by Wonder Warthog (Newly fledged NRA Life Member (after many years as an "annual renewal" sort))
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To: ckilmer

http://www.inside3dp.com/metal-3d-printing-lab-fab/


13 posted on 06/02/2014 6:52:17 PM PDT by Kennard
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To: null and void

PIng!


14 posted on 06/02/2014 7:01:54 PM PDT by Fractal Trader
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To: ckilmer; AFPhys; AD from SpringBay; ADemocratNoMore; aimhigh; AnalogReigns; archy; ...
3-D Printer Ping!


15 posted on 06/02/2014 8:21:55 PM PDT by null and void (Fascists never think they're fascists. They just think everybody should obey them.)
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To: ckilmer

It can print rocket engines, but can it print a 3D printer?


16 posted on 06/02/2014 8:52:37 PM PDT by ElkGroveDan (My tagline is in the shop.)
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To: Steely Tom

The ultra-heavy lift vehicle that will send SpaceX’s Mars Colonial Transporter to Mars will have 27 million lbs. of thrust at liftoff (maybe a little less).


17 posted on 06/02/2014 8:56:42 PM PDT by Jack Hydrazine (Pubbies = national collectivists; Dems = international collectivists; We need a second party!)
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To: ckilmer

No parachutes?

It’s gonna be fun plummetting down out of the sky waiting to see if those puppies light up - just before impact.


18 posted on 06/02/2014 9:08:05 PM PDT by Talisker (One who commands, must obey.)
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To: Talisker

I watched the presentation. It will have chutes. During reentry the rockets will self-test. If failure is detected, then chutes will deploy.


19 posted on 06/03/2014 12:52:31 AM PDT by catbertz
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To: Wonder Warthog

Search Ebay. CNC 320s go in the $600. range. I’ve seen used full-size industrial CNC units just above $1000 as well. . .


20 posted on 06/03/2014 4:21:53 AM PDT by Salgak (http://catalogoftehburningstoopid.blogspot.com 100% all-natural snark !)
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To: Salgak
"Search Ebay. CNC 320s go in the $600. range. I’ve seen used full-size industrial CNC units just above $1000 as well. . ."

Thnx. I'll give Ebay another look. Last time I checked (which I will admit was quite a while back), I didn't find much. Of course, that was before the Obama-inspired Depression got into full swing.....:^)

Any particular search terms you find give best results??

21 posted on 06/03/2014 7:28:54 AM PDT by Wonder Warthog (Newly fledged NRA Life Member (after many years as an "annual renewal" sort))
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To: Wonder Warthog

I just search on “CNC Mill”


22 posted on 06/03/2014 8:40:21 AM PDT by Salgak (http://catalogoftehburningstoopid.blogspot.com 100% all-natural snark !)
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To: Salgak
"I just search on “CNC Mill”"

Yup...worked for me also. Things in that category have really changed a LOT since my last visit..the size of the category has just exploded....and WAY more small stuff, and reasonably priced, even for new stuff.

Thnx again for the tip.

23 posted on 06/03/2014 10:11:40 AM PDT by Wonder Warthog (Newly fledged NRA Life Member (after many years as an "annual renewal" sort))
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