When 3D printers first started becoming mainstream, no one would’ve thought that people would 3D print aircraft components out of all things. However, it actually happened. Wuhan, China, is at the forefront of this achievement, producing the world’s first 3D-printed “piston rod axle” for landing gear.

The 3D Printing machine integrates casting, forging and milling – all of it!

This massive T-shaped component is visually indistinguishable from its traditionally made metal counterpart, measuring 1.5 meters long and weighing 240 kg. The key lies in overcoming a 3D-printing hurdle: creating parts prone to cracks. Professor Zhang Haiou’s team at Huazhong University cracked the code in 2019 with a new 3D printing machine that integrates casting, forging, and milling. This overcomes limitations by bridging the gap between traditional manufacturing processes.

China 3D Printing

The benefits are more than just substantial. Professor Haiou says that there’s a 90% material reduction compared to traditional methods, leading to significant cost savings and environmental advantages. Testing confirms the 3D-printed parts are even stronger than traditionally made components. Rigorous testing has confirmed its resilience.

This achievement marks a major milestone. Currently, only a few countries can produce large aircraft landing gear. Wuhan Tianyu Intelligent Manufacturing, the company behind the innovation, is the first to 3D-print such a critical part.

Wuhan Tianyu is a leader in 3D printing, with a history of collaborating with industry giants. This innovation has the long-term potential to completely revolutionize aircraft manufacturing by offering a more cost-effective and environmentally friendly approach. It will be hard to convince people to fly in a 3D-printed aircraft one day, that’s for sure. But so was the case with the first passenger flight in 1914. Let’s hope one day, 3D-printed aircraft are safe enough for commercial flights.

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