BMW first started the additive manufacturing of prototype parts back in 1991, for concept vehicles. By 2010, plastic-and metal-based processes were being rolled out, initially in smaller series, to produce items such as the additively manufactured water pump wheel in the DTM race cars. Further series production applications followed from 2012 on, with a range of components for the Rolls-Royce Phantom, BMW i8 Roadster (2017) and MINI John Cooper Works GP (2020), which contains no less than four 3D-printed components as standard.

Last year, the company produced about 300,000 parts by additive manufacturing. The Additive Manufacturing Campus currently employs up to 80 associates and operates about 50 industrial systems that work with metals and plastics. Another 50 systems are in operation at production sites around the world.

Access to the latest technologies is gained through long-standing partnerships with manufacturers and universities, and by successfully scouting for industry newcomers. Back in 2016, BMW i Ventures invested in the Silicon Valley-based company Carbon, whose Digital Light Synthesis technology achieved a breakthrough in planar processes, using a planar light projector to enable super-fast component production.

Further investments were made in 2017, when the company became involved with Desktop Metal, a start-up specialising in additive manufacturing of metal components and developing innovative, highly productive manufacturing procedures. Close collaborations with Desktop Metal continue. In the same year, BMW i Ventures invested in the US start-up Xometry, a platform for on-demand manufacturing.

The latest investment was in the German start-up ELISE, which allows engineers to produce component DNA containing all the technical requirements for the part, from load requirements and manufacturing restrictions to costs and potential optimisation parameters. ELISE then uses this DNA, along with established development tools, to automatically generate optimum components.

The pre-development unit of the Additive Manufacturing Campus optimises new technologies and materials for comprehensive use across the company. The main focus is on automating process chains that have previously required large amounts of manual work, to make 3D printing more economical and viable for use on an industrial scale over the longer term.

The Additive Manufacturing Campus is also making a contribution to series production of plastic parts. In the POLYLINE project, the focus is on aspects such as digitally linking process steps, and the development of a consistent quality assurance methodology for the entire process chain. The Additive Manufacturing Campus will provide the backdrop for the project’s consortium of 15 partners to develop and test a future-proof, fully linked, automated production line for plastic components. Findings from the project are expected to help reduce manufacturing costs by as much as 50 percent, making a vital contribution to series production. In addition, integrated quality assurance methods will increase the stability of technologies and make manufacturing more sustainable.

Along with component manufacturing, the team at the Campus provides personal consultations and training courses for BMW facilities around the world that all manufacture 3D-printing components already, be it for prototypes or production, or as country-specific parts for customers.

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Rolls Royce says that UltraFan will set new standards in efficiency and sustainability, offering a 25 per cent fuel reduction compared to the first generation of Trent engine, and deliver the same percentage reduction in emissions.

Efficiency improvement comes from the composite fan blades and fan case, which reduce weight on a twin-engine aircraft by 700kg, the equivalent of seven people travelling.

The engine which is due to start ground tests in 2021 features a new core architecture which maximises fuel efficiency and lowers emissions. Advanced ceramic matrix composites provide new heat resistant components that operate more effectively in high turbine temperatures and a new geared design will maximise high-thrust.

We have got all the building blocks in place, the design, the technologies, a brand-new testbed, and now we are actually seeing the engine come together.

Chris Cholerton, Rolls-Royce, President – Civil Aerospace

The fan blades are created through the build-up of hundreds of layers of carbon-fibre materials, pre-filled with enhanced, resin material. Heat and pressure are then applied, and each blade is finished with a thin titanium leading edge, which offers extreme protection against erosion, foreign objects and bird strikes.

Composite blades have already been extensively tested on an Advanced Low-Pressure System development engine, including in-flight testing on the Rolls-Royce Flying Test Bed.

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The fan blades and fan cases being made at the facility are a feature of the Rolls-Royce UltraFan engine demonstrator, a new engine design which will reduce fuel burn and CO2 by at least 25% compared to the first Trent engine.

The new facility will use low-energy, very low emissions processes and features state-of-the-art automated manufacturing methods and materials. It will maximise the use of raw materials, reducing waste. with the company targeting zero emissions at its operations and facilities by 2030.

The facility will focus on carbon fibre composites, which are used in the aerospace industry to reduce weight significantly. The lighter an engine is, the less fuel it burns, creating fewer emissions. A Rolls-Royce fan system made with carbon fibre composites can save almost 700kg per aircraft, the equivalent of seven passengers and their luggage.

The fan blades are made by manufacturing techniques that build up hundreds of layers of carbon fibre materials, pre-filled with state-of-the-art toughness-enhanced resin material. Heat and pressure are then applied, and each blade is finished with a thin titanium leading edge, which offers extreme protection against erosion, foreign objects and bird strikes.

From January, the facility will begin making fan blades and cases for the UltraFan demonstrator engine. The composite system for the UltraFan engine demonstrator is taking shape, and different parts have completed aerodynamic performance, bird-strike, containment, icing and water ingestion tests, as well as ground and flight testing.

Rolls-Royce has been involved in developing carbon fibre technologies for several decades and already uses the material for parts within its engines. The new facility will take this technology to the next level.

It will benefit from manufacturing techniques that have been developed in partnership with the National Composites Centre in Bristol, and research conducted at the Rolls-Royce University Technology Centre at the University of Bristol, as well as several other universities and research centres based in the UK and in Europe.

The facility has secured 150 jobs in Bristol. An existing composite manufacturing technology facility, along with around 30 employees, has been transferred from the Isle of Wight. Since 2008, the UK Government has provided funding and support for Rolls-Royce composite technology research and development, including £7.4m of funding to support the Isle of Wight facility. The equipment from here has been moved and developed further at the new facility in Bristol.

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The company held a dedication ceremony with federal, state and local officials, customers and employees at the new facility. Rolls-Royce purchased Hyper-Therm High-Temperature Composites back in May 2013 and continues to grow and invest with this new “CMC technology hub” located in Cypress, Calif.

Rolls-Royce President and CEO of North America, Marion Blakey said this expansion will develop novel solutions to improve performance of future aircraft engines.

The development of lighter, stronger, composite fibre components is just part of our commitment to continuously improve the performance of our products by focusing on lowering fuel consumption, emissions and noise. The team here in Cypress will be dedicated to seeing the commercial application of these technologies that will soon be adopted into advanced manufacturing production methods for gas turbine components.

Ceramic matrix composites (CMCs) offer multiple advantages for a range of high-tech industries such as aerospace and other applications with demanding thermal and mechanical requirements. CMCs deliver the high temperature capability of ceramics with the strength and reliability that is required for gas turbine engine applications, but weigh less than current alloys. CMC components help save on fuel costs since they are lighter weight and require less cooling over traditional nickel-based components.

The facility will develop production-ready manufacturing processes and produce components that will be used for engine test programs. From there, manufacturing processes refined in Cypress facility will be applied to a future dedicated production facility for manufacturing of engine components.

Since Rolls-Royce acquired Hyper-Therm in 2013, it has grown from 15 employees to nearly 50 positions today. The company expects to hire at least 10 more people this year with the potential for forty more positions as production and testing of products increase. In late 2015, Rolls-Royce received tax incentives totalling nearly $735,000 for the purchase of the high precision machinery, from the California Alternative Energy and Advanced Transportation Financing Authority.

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The company has recently completed their “CoFusion” project with funding from the National Aerospace Technology Exploitation Programme (NATEP), in partnership with the UK National Composites Centre, TenCate Advanced Composites and Rolls Royce. The project involved work to optimise the efficiency and applicability of an innovative, low-cost thermoplastic composite welding process.

The “CoFusion” project demonstrated that carbon/polyphenylene sulfide (PPS) composite thermoformed components can be reliably welded to form complex assemblies utilising resistive composite welding elements that contain no metal meshes or inserts.

The resulting welded components feature consistent high strength and fatigue properties that have been demonstrated at both coupon and component levels. Low cost equipment and materials can be used and the heating to welding temperature takes only three minutes. The process is not limited to flat components; panels with significant curvature can be welded reliably. All resulting welds are high quality with no voids passing standard ultrasonic Non-destructive Testing (NDT) specifications.

Welded top-hat sandwich panels were produced and structurally compared by torsional strength and fatigue testing to identical riveted parts. The welded component had higher stiffness and greater strength reaching five times that of the riveted component. The fatigue performance of the welded component was also significantly superior with no damage at 350,000 cycles in comparison to the riveted parts that only survived 50,000 cycles.

Wayne Exton, CEO of AGC AeroComposites said;

The CoFusion project was a tremendous opportunity for our company to pursue advances in composite technology, the ability to weld thermoformed thermoplastic composite components to form structurally efficient light weight assemblies allows us to continue to provide our global customer base with innovative, high quality, cost-effective products.

The NATEP funding ran for 18 months and had a total budget of £275,000; half of which was funded through NATEP

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Efficient and lightweight propulsion is key to reducing the environmental impact of a modern yacht, and the luxury yacht builder has been working with Rolls Royce to create this new propulsion system for their new range of megayachts.

The new Azipull Carbon 65 uses carbon fibre material for load carrying parts, resulting in a substantial reduction of the propulsion system’s weight. The new thrusters also facilitate a better vessel lay out while maintaining high propulsion efficiency, excellent manoeuvring capabilities and easy maintenance.

Designed at the beginning for fast yachts, with further applications in passenger vessels and work boats, the Azipull Carbon brings to the market a lightweight, reliable and highly efficient propulsion system with very low noise and vibration levels.

The first thruster in the series, AZP C65, is designed for a power rating of 2 MW and fitted with a fixed pitch, pulling type propeller – meaning the propeller faces forward. The driveline is designed with two spiral bevel gear sets, installed in a supporting structure that ensures optimum load carrying capacity in all operating conditions. The thruster can be steered using a hydraulic system. An Automation and Control system, based on Rolls-Royce’s Common Controls building blocks, has also been developed to match the new thrusters, which each weigh only 2,800 kg (dry).

The contract covers a number of thrusters, planned for delivery over the next three years and delivered to RINA Rules for Classification of Yachts. The first yacht, a 125 ft Fast Displacement called IRONMAN has already been delivered. Hulls two and three are under construction with delivery expected in the next few months.

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The Rolls-Royce carbon/titanium blades are a key feature of the new Advance engine design, unveiled last year, which will offer at least 20% less fuel burn and CO2 emissions than the first generation of the Trent aero-engine. The blades and associated composite engine casings will form part of the new CTi fan system that could reduce weight by up to 1,500lb per aircraft, the equivalent of carrying seven more passengers and their luggage.

Tony Wood, Rolls-Royce, President – Aerospace said:

This state-of-the-art facility will give us the opportunity to further develop our world-leading composite technology and manufacturing techniques for our next generation of engine design. These high-technology lightweight components have the potential to significantly improve the fuel consumption and emissions of future aircraft through our new Rolls-Royce Advance and UltraFan demonstrators.

The new facility will be developed within an existing building alongside Rolls-Royce’s new facility for carbon-fibre electrical harness rafts, currently being constructed on the Bristol site. Both facilities will benefit from manufacturing techniques being developed in partnership with the National Composites Centre in Bristol, and research being conducted at the Rolls-Royce University Technology Centre at the University of Bristol.

Rolls-Royce’s existing CTi manufacturing technology capability, along with around 40 current employees, will be transferred from its composites location on the Isle of Wight during 2017, meaning a potential additional 80 roles could be created in Bristol over the next four years. The UK Government has provided an additional £7.4m in funding support to the establishment of the pre-production facility and equipment at the Isle of Wight facility and these will be further developed at the new pre-production Rolls-Royce facility in Bristol.

A set of the CTi fan blades, incorporated into a Trent 1000 ‘donor’ engine, successfully completed a full flight test programme on a Rolls-Royce 747 flying test bed at Tucson, Arizona, USA back in December last year. A rigorous testing programme of the complete fan set continues to take place throughout 2015.

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Six projects will share £80 million for aerospace research to help deliver growth and innovation in key areas of technology. This funding comes from a £2 billion pot committed jointly by industry and government as part of our industrial strategy, through the Aerospace Technology Institute (ATI). The projects involve 18 companies, 11 academic or research institutions and 5 Catapult centres from across the UK.

The 6 projects receiving funding from the ATI are:

• £14 million for 9 partners led by Rolls-Royce – and including McLaren Racing – for high-tech research projects, using Formula 1 know-how to help develop high power gearboxes for future jet engines.
• £14 million for 9 partners, led by Airbus, to design improved landing gear for future aircraft, including introducing electric taxi technology so that engines can be switched off immediately after landing, saving fuel and reducing emissions.
• £9 million for 7 companies, led by Airbus Group, to improve the management of power used on aircraft and replace hydraulic systems with electric control systems. This will deliver lighter, greener aircraft, reducing CO2 emissions and saving airlines up to an estimated £2 billion annually.
• £10 million for 5 companies, led by GE Aviation Systems, to develop advanced printed circuit board test equipment, to improve the manufacture of high quality electronics that can operate in harsh environments.
• £17 million for a project led by Rolls-Royce working with suppliers to develop new concepts for future engine architectures to improve environmental performance.
• £16 million for Airbus, Marshalls ADG and Bristol, Loughborough and Cranfield Universities to research and test innovations in wing design.

Along with the Governments investment, top aerospace firms are also investing £20 million in the skills that will take the sector to new heights. The funding will provide a boost to industry skills at all levels, with the creation of new high-tech Masters courses, apprenticeships and careers opportunities for young people and graduates alike.

Led by global aircraft manufacturer Airbus, through the Aerospace Growth Partnership, the skills project also sees leading employers including Augusta Westland in Yeovil, BAE in Hook and GKN in South Gloucestershire joining together to develop existing and future aerospace talent.

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The interior looks like its ram-raided a carbon fibre manufacturing facility, gone is the traditional refined wood interior, replaced instead by the magical black stuff. Carbon fibre can be found literally everywhere in this car’s interior, from the dashboard and coach door panels to the steering wheel and instrument dials. The carbon fibre elements have been contrasted with Hotspur Red leather accents, while the seats are upholstered in black leather.

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Opened in 2007, and expanded in 2013, the Rolls-Royce Outdoor Jet Engine Testing Facility at Stennis is one of three test sites the company own around the world. The facility conducts specialist development engine testing including noise, crosswind, thrust reverse, cyclic and endurance testing on all current Rolls-Royce large engine types and employs nearly 50 people at the facility.

The fan system successfully completed crosswind testing using a Trent 1000 Advanced Low Pressure System technology engine. Confirmation of the new fan design performance will enable the programme to move on to the next phase of demonstration, which includes flight testing.

The fan system includes carbon/titanium fan blades and a composite casing that reduce weight by up to 1,500lb per aircraft, the equivalent of carrying seven more passengers at no cost. The engine design will also offer at least 20% less fuel burn and CO₂ emissions than the first generation of Trent engine.

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