Honeywell Brings
Futuristic 3-D Printing
Design Skills into Focus
for Student Engineers

August 24, 2016 | Author: Donald Godfrey

Additive manufacturing – also known as 3-D printing – continues to advance into the high-tech manufacturing marketplace. That is creating an increased need for engineers who understand the design freedoms and limitations of this critical skill set.

While textbooks are expected to focus ever more intently on “Design for Additive Manufacturing” over the next 10 years, Honeywell is taking a proactive approach now.

Honeywell is working with university engineering programs to start developing student engineers who will graduate with the 3-D printing background and know-how to meet the needs of high-tech employers.

Empowering Student Knowledge

Honeywell is partnering with the Ira A. Fulton Schools of Engineering at Arizona State University, which features an impressive 3-D printing lab at its Polytechnic campus. It offers the faculty expertise, industry partnerships and state-of-the-art facilities to give students a thorough grounding in additive manufacturing.

To demonstrate how industry is putting 3-D design and manufacturing into practice, Honeywell brings ASU students to its new additive manufacturing laboratories in Phoenix. Some work as interns or co-op students, while others visit for a first-hand look at how Honeywell is using the new technologies and integrating them into component designs.

Continuing its long tradition of sponsoring senior capstone projects at ASU’s Polytechnic and Tempe, Ariz., campuses, Honeywell also is working this year with four student projects associated with 3-D printing. The goal is to help the company and the students learn about each other and the new technology.

Learning through Collaboration

Brittany NezAnother example of the partnership is Honeywell’s collaboration with ASU student Brittany Nez, who is studying 3-D printing and aircraft manufacturing though a fellowship from the ASU/NASA Space Grant program.

A junior in aerospace engineering, Nez is researching 3D additive manufacturing methods under the guidance of John Parsey, a professor of practice in ASU’s Polytechnic Schools. Nez is evaluating 3-D printed test specimens against wrought alloys of the same chemistry, using test specimens built with powder bed fusion technology for metal.

Her research focuses on understanding the mechanical properties of 3-D printed test specimens of specific nickel alloys, and if those mechanical properties are suitable for aerospace applications. Honeywell provides Nez with 3-D manufactured samples to enable thermal conductivity, stress tension and hardness testing – all part of determining if the printed materials can withstand the requirements established by the component design.

Continuing the 3-D Design Revolution

Understanding the new design freedoms offered through the powder bed fusion technology will require cultural change. Engineers graduating from engineering and technical institutions must understand – and be comfortable with – its capabilities. New labs and technical courses must be designed to lay the groundwork of basic knowledge for both students and existing employees in the workforce.

At ASU, the Polytechnic campus currently is offering its students a wide display of 3-D printing technologies such as stereolithography, fused deposition modeling, and polyjet printing, with powder bed fusion for both polymers and metals. Its additive manufacturing labs are equipped with thermal imaging/measurement equipment, scanning electron microscopy, optical microscopy, metrology, metallography, and materials testing capabilities.

The faculty’s expertise ranges from material and process development, scalable Nano manufacturing and laser processing to meta-materials, micro-machining, nanomaterial synthesis and characterization and carbon nanocomposites. New areas of expertise will focus on polymer rheology and processing, metallurgy and design for additive manufacturing.

Keng HsuCurrent efforts focus on advancing additive manufacturing technology maturity and innovation at both the fundamental research and engineering development levels in four thrusts states Dr. Keng Hsu.

  1. Materials characterization and development of application-driven, next-generation materials
  2. Additive manufacturing process optimization and integration and new process development
  3. Development of physics-based modeling of additive manufacturing processes and in-process diagnostics for a close-looped, design-optimization-fabrication-characterization approach
  4. Disruptive next-generation additive manufacturing processes that enables multi-material voxel 3D printing of systems and devices.
Donald Godfrey

Donald Godfrey

Donald Godfrey is an engineering fellow at Honeywell Aerospace.

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