3D printing is coming of age in numerous ways. On a large scale, MIT researchers built a 50-foot-wide, 12-foot tall igloo in just 13 hours. They’ve also debuted the first completely 3D-printed rocket engine. On a much smaller level, our own Sean Buckley printed a little d-pad for his Nintendo Switch, while medical researchers have produced a 3D-printed patch that can heal scarred heart tissue. Now we’re seeing this technology coming to the industrial world with a new laser-powered metal 3D printer from GE . GE Additive is a new business under the larger GE umbrella. It is developing what it calls “the world’s largest laser-powered 3D printer” to create parts that fit within one cubic meter cubic of space. “The machine will 3D print aviation parts suitable for making jet engine structural components and parts for single-aisle aircraft, ” said GE Additive’s Mohammad Ehteshami in a statement . “It will also be applicable for manufacturers in the automotive, power, and oil and gas industries.” Additive printers fuse fine layers of powdered metal with a laser beam to print objects. The new process could make complex parts like jet engine components easier and less costly to make than traditional casting and welding techniques. GE Aviation is already printing fuel nozzles for jet engines that will be found in Airbus, Boeing and narrow-body jets. GE has a prototype large-scale metal prnter, called ATLAS, that can print 2D objects up to 1 meter long, but the new one will extend that to a third dimension. Beta versions of the new printer should be ready by the end of this year, according to Ehteshami, with a production version slated for 2018. Source: GE Reports
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GE is working on a massive 3D printer for jet engine parts
If you’re designing urban homes for Japan, you’ve automatically got two built-in problems: Earthquakes and tiny building footprints. Japan’s seismic woes are well-known, and the nation’s space-tight cities mean you’re always dealing with narrow frontage. The traditional way to combat the former is to use shear walls, which combine bracing and cladding in such a way as to prevent lateral motion. (Think of an unclad wall made from vertical studs, and how it can potentially parallelogram if the floor or ceiling moves; nail some sheets of structural plywood to it and the problem is basically solved.) The traditional way to combat the latter is to design spaces that admit a lot of sunlight and ventilation through that narrow piece of frontage. But that openness doesn’t jive with shear walls, which by definition are clad. Here with the solution is architect Kiyoshi Kasai and his ” Wooden Box 212 ” construction method, which uses wood yet enables large, column- and partition-free spaces. As he describes the issue (roughly translated from Japanese), With narrow-frontage urban housing there is a conflict with providing a window for lighting, ventilation and entrance and reconciling that with a shear wall on the same side…. The design preference in recent years has been to seek a sense of transparency and openness via a wide opening in the outer wall surface of the housing, but achieving this with conventional wood is difficult. (more…) 
Something very strange happened in the R&D lab of a UK-based electronics engineering company. A research team at Roke Manor Research was working on text-based radio frequency systems when a team member suddenly detected a signal—coming from a random bag of components off to the side. A small movement had apparently turned mechanical energy into electrical energy within the bag. After figuring out how this phenomena occurred, a Roke team subsequently harnessed it and created a new tiny tracking device. Their invention works over a greater distance than most existing tags, and here’s the killer quality that makes it really different from nearly all tracking devices: It works without batteries. The device is called Agitate and it’s a self-charging miniature device, no larger than a quarter. The agitate tag’s signal “can be tracked through walls and up to 20 kilometres in built-up areas, ” writes the company, “with an estimated range of 200 kilometres in free space.” So how does it work? Basically Agitate is made of two plates, one is metal and the other a charged material. When either of the two plates are moved, even just slightly, mechanical energy is turned into electrical and is used to transmit a radio pulse. The signal only lasts a few seconds but is more powerful than a cell phone. And it’s very precise—the shorter the radio pulse, the more precise the signal to a specific location. (more…) 
Anyone who’s seen James Cameron’s Aliens cannot forget the images of 1.) Ripley in a cargo-loader exoskeleton, and 2.) Vasquez prowling the corridors with that body-mounted machine gun on the swing arm. That was back in 1986; now it’s 2013, and not only have these designs actually come to pass, but they’ve been combined. As we previously reported , Lockheed Martin licensed a company called Ekso Bionics’ technology to develop the HULC , or Human Universal Load Carrier. It’s got the power-assist legs and the body-supported gun mount: While Ekso Bionics is targeting the consumer market, enabling paraplegics to walk again, Lockheed has initially gone military. However, they’re reportedly creating a version of the HULC called the Mantis, for industrial applications. As Bloomberg News reports , The machines may follow a classic arc from Pentagon research project to fixture on an assembly line, similar to the development of lasers, said Paul Saffo, managing director of foresight at investment advisory firm Discern in San Francisco. “The medical devices get the most attention, the military funds it and the first mass application is industrial,” Saffo said in a telephone interview. [Mantis is aimed at] any industry in which workers must hold heavy equipment that can cause fatigue and back injuries…. Mantis has a mechanical extension for a wearer’s arm and absorbs the strain from hefting a grinder or sander, [Lockheed business development manager Keith] Maxwell said. Tests found productivity gains of more than 30 percent, he said, and wearers showed their Macarena footwork to demonstrate the suits’ flexibility. “It turns workers away from being a weightlifter and into a craftsman,” Maxwell said. I’m all for Construction Worker Exoskeletons—as long as the power tools are not integrated, but remain separate objects that you pick up. Because once they start replacing the user’s hands with built-in angle grinders and magazine-fed nail guns, we’re going to have a problem. Last year, I watched a construction worker fight a cabdriver in front of my building; the hack didn’t stand a chance. The last thing I want to see is an angry frame carpenter tramping off the jobsite in one of these things, ready to settle someone’s hash with his Forstner-bit fingers and chopsaw hands. (more…)