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BAE Systems-Backed Project to Transform NDT for 3D Printed Aircraft Components

20 Mar 2023

BAE System


The aerospace and defense industries are known for their rigorous demands on component quality and reliability, making non-destructive testing (NDT) an integral part of the production process. NDT techniques allow manufacturers to detect flaws and irregularities in components without affecting their structural integrity, ensuring maximum safety and performance. The demand for NDT services in aviation and defense continues to rise, driven by the need for regular maintenance and inspections of aircraft components, as well as government regulations and industry standards. In addition, the growing number of space activities, such as the deployment of satellite constellations by companies like SpaceX and Amazon, is set to fuel the NDT services market. 

According to the BIS Research analysis, the global non-destructive testing services in aerospace and defense market is estimated to reach $1.81 billion in 2033 from $1.29 billion in 2022, at a CAGR of 3.34% during the forecast period 2023-2033. 


In this context, the University of Sheffield Advanced Manufacturing Research Centre (AMRC) North West has partnered with Theta Technologies to develop a game-changing NDT product for metal additive manufacturing, with the potential to transform the way NDT is implemented in critical industries such as aerospace, defense, automotive and nuclear energy. 

Here’s the complete story. 

Promising NDT Products for Aerospace and Defence 3D Printed Parts

Theta Technologies has developed a commercially available NDT product called the RD1-TT, which utilizes nonlinear resonance techniques to detect flaws in 3D-printed metal parts. The company is working with AMRC Northwest and BAE Systems, a U.K based leading aerospace company, to test the product's suitability for a range of components. The RD1-TT promises faster, easier, and more cost-effective NDT for 3D-printed metal components, making it possible to implement NDT at more stages throughout the additive manufacturing (AM) process.

The significance of this development cannot be overstated. AM is an increasingly important part of the production process across many industries, and the ability to use NDT throughout the process and rapidly eliminate defects will revolutionize the way components are manufactured. The technology is of particular interest to the aerospace, defense, automotive, and nuclear energy industries, where component quality and reliability are essential.

The RD1-TT is based on nonlinear acoustics and works by exciting components using a range of different sources before monitoring the tested part for non-linearity using a detector system. The technology has the potential to be a game-changer for metal additive manufacturing testing processes, making it possible to detect and eliminate defects more quickly and easily. As a result of the collaboration, an RD1-TT unit will be based within the AMRC North West facility, where it will be testing a variety of BAE Systems' manufactured components, including 3D-printed metals and composites.

The benefits of this development are clear. The RD1-TT will not only allow for more comprehensive and effective testing of 3D-printed metal components, but it will also pave the way for further developments in NDT for AM. The collaboration between Theta Technologies, AMRC North West, and BAE Systems has resulted in this exciting development that has the potential to transform the way we manufacture and test components.

Testing the Feasibility of the RD1-TT

AMRC North West research director Dr. James Hughes explains the importance of collaboration. He stated that "We are very excited to participate in this project to test the feasibility of this new NDT technique developed by Theta Technologies and to assess the usability as an evaluation tool needed to address the quality control challenges encountered in AM. As a part of the consortium, AMRC Northwest will work on the measurement system analysis and applicability of the technique on a wide range of products with different materials and geometries provided by BAE Systems."

Steve Butler, CEO of Theta Technologies, says this collaboration represents a significant step forward. "To have BAE Systems, a major international manufacturer, express such an interest in our technology is a tremendous boost for us. This collaboration will help us to gather further evidence of our technologies' capabilities and allow us to validate what we know it can do."

Butler says that it is important for Theta Technologies to use this project to understand the challenges that manufacturers face with regard to their manufacturing and testing processes. This will allow the company to continue developing existing and future products to maximize the benefit to its customers.

Collaboration with AMRC Northwest and BAE Systems

Theta Technologies has collaborated with AMRC Northwest and BAE Systems to test the suitability of the RD1-TT system for testing a range of BAE Systems components. The AMRC Northwest research director, Dr. James Hughes, said that they are very excited to participate in this project to test the feasibility of this new NDT technique developed by Theta Technologies and to assess its usability as an evaluation tool needed to address the quality control challenges encountered in AM. As a result of the industrial research collaboration, an RD1-TT unit will be based within the AMRC Northwest facility, where it will be testing a variety of BAE Systems’ manufactured components, including 3D printed metals and composites.

Kevin Pickup, lead technologist for product verification, BAE Systems Air sector, said that they recognize new opportunities and advances in inspection capability as they evolve their manufacturing processes. They are impressed by Theta Technologies' innovative NDT methods and are excited to work together to assess the RD1-TT and to understand how it can be effectively embedded within their production lines and across their product range.

Conclusion

The development of the RD1-TT system by Theta Technologies promises to revolutionize the non-destructive testing of 3D-printed parts in the aerospace and defense industries. The collaboration between Theta Technologies, AMRC Northwest, and BAE Systems is a significant step forward in the validation of this technology and the development of future products that can maximize the benefits to customers. With the increasing use of AM in production processes, the need for efficient and cost-effective non-destructive testing methods has become more important than ever. The RD1-TT system could potentially change the future of metal additive manufacturing testing processes, and this is an exciting development for the industry.

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