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A new generation of material: Printed Composite Honeycomb by Ultimate Jets.

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A new generation of material: Printed Composite Honeycomb by Ultimate Jets.

Old 09-02-2014, 09:25 AM
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FalconWings
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edited: never mind the answer was above!
Old 09-02-2014, 10:08 AM
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olnico
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I am using nylon for certain types of parts, but these new materials are 100% nylon free.
The biggest reason for this is that I am looking for material that are very easy to glue. Nylon is a release agent. So very glue un-friendly!!!
Old 09-02-2014, 12:12 PM
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Nylon totally sucks when it comes to bonding! very difficult to work with. You can fusion weld it but it is not something for the average modeler.

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Old 09-02-2014, 02:52 PM
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Just awesome! Cool to see the outstanding minds we have in our hobby. I got your PM Oli, I'll look at servos again tonight.
Old 09-02-2014, 03:53 PM
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+1

Hello FEJ all over again.
Old 09-02-2014, 05:13 PM
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Originally Posted by patf
Amazing stuff Oli!

Of course. Consider the source!
Old 09-02-2014, 09:10 PM
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Thanks guys.
This is the future of aerospace design.
For example, consider the manufacture of a propeller. Being able to print an inner core that is 3D honeycomb, ballistic grade and conforms to the mold shape by 2/10 mm opens a new area in composite design.
BTW the CAD software we use to compute composite aero structure resistance are not able to modelize such a material yet. So the gain in weight and resistance for very complex parts and whole assemblies is unknown yet!
Old 09-03-2014, 06:27 AM
  #33  
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Originally Posted by olnico
Thanks guys.
This is the future of aerospace design.
For example, consider the manufacture of a propeller. Being able to print an inner core that is 3D honeycomb, ballistic grade and conforms to the mold shape by 2/10 mm opens a new area in composite design.
BTW the CAD software we use to compute composite aero structure resistance are not able to modelize such a material yet. So the gain in weight and resistance for very complex parts and whole assemblies is unknown yet!
Oliver, future is here. They are being experimented on Heli Rotor Blades at this moment, which are currently made of composite honeycomb. Many folks dont realize the technology inside a helicopter blade/propeller, specifically when it comes to the application of smart materials. Stuff that used to be mechanically controlled can now be controlled by material selection. Selective Additive Mfg is a game changer! Not to mention the impact on manufacturing!!!
Old 09-03-2014, 08:47 AM
  #34  
Greg G
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Additive manufacturing with new composites materials is here and evolving. Not sure I would trust a propellor made from only FDM PC/ABS for a high performance application even if you call it "Ballistic Grade". I have made toy grade helicopter blades from stereolithography/epoxy for functional prototypes.

Last edited by Greg G; 09-03-2014 at 09:03 AM.
Old 09-03-2014, 09:31 AM
  #35  
olnico
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Originally Posted by FalconWings
Oliver, future is here. They are being experimented on Heli Rotor Blades at this moment, which are currently made of composite honeycomb
I do agree. Future is here.
PLACAR ( Poly Lactic Acid nano CARbone reinforced material) 3D honeycomb printed gear doors for the Diamond:




This material has a high ratio of nano carbon fibers and is quite difficult to process ( requires high printing temperatures and a hot bed as well as a special surface treatment before processing). I also had to make a specific 0.65 mm laser drilled printing nozzle for this purpose. Note that the piano hinge recess and control horns are included in the printing process.
The part is crazy light ( less than 10 grs ) and extremely stiff. Very impressive material.

Last edited by olnico; 09-03-2014 at 09:34 AM.
Old 09-03-2014, 10:02 AM
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Oli, now all you need is a 10'x10'x4' printer and get to work! :-)

Imagine one piece wings, with cross-braced integral ribs exactly where they are needed! Ahh....the possibilities!!
Old 09-03-2014, 11:12 AM
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olnico
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Originally Posted by FalconWings

Oli, now all you need is a 10'x10'x4' printer and get to work! :-)
Ooooch, big $$$$$$...
Old 09-03-2014, 11:16 AM
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Originally Posted by Greg G
Not sure I would trust a propellor made from only FDM PC/ABS for a high performance application even if you call it "Ballistic Grade".
Only the core is made from this material. The layup is still prepreg HMD carbon fiber. This is where things get amazing. You get a ballistic grade core with super stiff layup

I have some parts made like this that I cannot show here. I can ensure you that this stuff is absolutely amazing.
Old 09-08-2014, 02:14 AM
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A sample of the 3 axis honeycomb structure printed from PYCABS.

On the z axis, the structure is octogonal.



On the x and y axis the structure is exagonal.

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Last edited by olnico; 09-08-2014 at 02:16 AM.
Old 09-08-2014, 06:05 AM
  #40  
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Interesting stuff Oli !!

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