A team from the University of Southampton has used 3D printing techniques to build a working UAV from the ground up in just under a week. The team, led by Andy Keane and Jim Scanlan, demonstrated their effort at an air strip just a little down the road from Stonehenge. The 1.5 meter wing span, ultra-low-drag, aircraft successfully flew showing it is possible to build for each individual application.
At 100 micrometers (4 thousands) at a time, a laser traces out the 2D cross section of the design. The laser can "print" with many different types of materials, from polyamide plastic to stainless steel or titanium powder. When forming parts with the metallic powder, the team stated that it is as strong as if the parts were machined from raw/bare metal. To create a stronger formed part, an electron laser sintering is used, instead of the conventional laser, to melt the powder completely.
Of course, the electronics in the craft are not printed. At least not yet. http://www.element14.com/community/community/doittogetherblog/blog/2011/07/14/grow-electronics-by-the-molecule
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