When the U.S. Army needed a Kiowa helicopter for a raft of tests to hone the aircraft’s military performance, it didn’t rescue a helo from the scrap heap and repurpose it.
Instead, the Army turned to NASA Langley Research Center in Hampton, where engineers downloaded computer-aided design files to a 3D printer and began to crank out a scaled model of a helicopter, layer by layer, piece by piece.
And when technicians snapped those pieces together, they had a plastic model of a Kiowa at 37 percent scale to run through rigorous tests in their subsonic wind tunnel.
Last year, NASA administrator Charles Bolden sent a congratulatory message to Langley’s Kiowa team telling them the project represented more than a “demonstrable savings on actual flight tests.”
“It also represents a significant reduction in risk to test pilots and test flight engineers who would have had to fly some of the high-risk ordnance carriage and delivery profiles had we not been able to model them as part of this project,” Bolden wrote.
Building aircraft models for wind tunnel tests is but one way engineers and researchers in Hampton Roads are harnessing 3D printing technology, which has grown beyond just making plastic Lego-like parts.NASA Langley has a stable of a dozen or so 3D printers that work with powdered metal or metal wire, with resins, plastics and even wax. By depositing layer upon layer of plastic or by melting metals with an electron beam or laser, machines can grow objects from tiny widgets to
Article source: http://www.military.com/daily-news/2014/12/04/3d-printers-build-the-impossible-for-hampton-roads-scientists.html


