Bell, Ingersoll Machine Tools 3D-print rotor blade trim tool

Ingersoll Machine Tools Inc. and Bell Textron Inc. have collaborated using a large format 3D printer to successfully manufacture a 22ft long vacuum trim tool for producing main rotor blade components.

The effort used Ingersoll’s hybrid large format MasterPrint gantry type 3D printer and 5-axis milling machine housed at Ingersoll’s headquarters facility in Rockford, Illinois.

“We are continuously testing and advancing MasterPrint in our Development Center” said Chip Storie, CEO at Ingersoll “Among Ingersoll’s short-term objectives is for MasterPrint to 3D-print molds for aerospace that preserve the geometrical properties and tolerances, vacuum integrity, and autoclave resilience normally obtained with traditional technology, but with the cost and time reduction only additive manufacturing can offer. The relentless progress our MasterPrint process has made in 2020 has finally made this target attainable”.

This production tooling effort 3D printed 1,150 lb of ABS material with 20% chopped carbon fiber fill. The printing process was completed as a single part in a continuous 75-hour operation. After printing, the mold surfaces and tooling location features were machined to finished dimensions by exchanging the print module for the 5-axis milling head which is changeable on the MasterPrint machine. The machining was completed in one week and the final part achieved full vacuum tightness. The Ingersoll machine uses the Siemens 840D CNC control system for controlling both the machining and the 3D printing.

Critical time savings was achieved through the 3D print fabrication and efficient 5-axis machining operations. The additive and subtractive manufacturing processes were seamlessly co-engineered in the native CAD software format. The traditional build cycle for a typical mold in aluminum such as this using standard methods is typically 4 to 5 months. This manufacturing process was completed in a matter of weeks.

“For many years Bell has utilized composite materials for manufacturing airframe components, including components produced on an Ingersoll Machine Tools Tape Layer machines. These similar materials are now being utilized for manufacturing the molds that form the airframe components.,” says James Cordell, Bell senior manager of process stability. “Utilizing this rapid manufacturing equipment will allow Bell to greatly accelerate our development of tooling for many applications within the Bell organization.”

Ingersoll Machine Tools has played an important role in enabling breakthrough airframe production techniques for major aircraft designs around the world and appreciates the opportunity to support Bell in building their future.

The Ingersoll product lineup includes MasterMill, PowerMill and SuperProfiler for accurate, reliable, high-speed milling and trimming of large, complex-geometry parts made of aluminum, titanium and hard metals; Mongoose and Mongoose Hybrid, for the composite manufacturing of aircraft, rocket, and vessel structures; MasterPrint, the largest existing thermoplastic 3D printer, capable to produce extra-large, hollow, parts in a single piece for the aerospace and the marine sectors. Ingersoll runs the same machines at its Development Center to manufacture key-components for many aerospace and defense programs. Ingersoll is part of the Camozzi Machine Tools division of the Camozzi Group.