ABSTRACT
Additive manufacturing (AM) offers a means of facilitating sensor placement within a larger complex component. AM is especially attractive for the manufacture of components from titanium. Titanium is a difficult material to use in the production of solid components, because of its brittle nature and its phase change properties. Weight is a critical concern in unmanned aircraft, and AM offers a feasible means of producing engine components out of titanium, which is much lighter than steel. AM, also known as three-dimensional (3D) printing, has gained notable attention as a means of rapid prototyping and manufacturing small quantities of specialized components. Aluminum and copper are more often suited to the ultrasonic AM process, but progress is being made in their use with other print processes. AM provided a cost- and time-effective means of producing this prototype head by eliminating the mold development step.
