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* * * * * * * * 3D PRINTING Chief armament engineer Richard FINCK Direction des affaires internationales, stratégiques et technologiques Secrétariat Général de la Défense et de la Sécurité Nationale 3D PRINTING FOR AEROSPACE: The THOR UAV The UAV, dubbed “Thor” for “Test of High-Tech Objectives in Reality,” is a massive 4 m (13 ft) in length, has a 4-m (13-ft) wingspan and weighs 25 kg (55 lbs) was unveiled this month by Aibus. Manufacturing drones isn’t new for Airbus, but 3D printing them is. Thor is made up of about 50 3D-printed parts, two electric engines and a remote control. The 3D printing process for Thor lasted roughly one month, and the production cost was estimated to be around 20 000 €.? This short manufacturing period is a key reason behind Airbus’ decision to 3D print Thor, as the flexibility that 3D printing offers could allow designers and engineers to create new aircraft on the fly. As Peter Sander, head of emerging technologies and concepts at Airbus, explained in his Innovation Days presentation, You can [3D] print this kind of aircraft in four weeks. It has low lead times for fast track developments.? With Thor acting as a small test bed, Airbus hopes to demonstrate that the same flexible design and manufacturing approach could be applied to full-scale aircraft. Although Airbus’ dream of a fully 3D-printed aircraft may not be realized for some time, this methodology could be applied to the numerous 3D printing endeavors already being pursued by the company: 3D-printed fuel nozzles within its A320neo, numerous components for the A350 XWB, bionic cabin partitions, 3D-printed fuselage and engine pylon parts. 3D Printing and additive manufacturing 3D printing, rapid prototyping or freeform fabrication, is “the process of joining materials to make objects from 3D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies” such as machining. The term 3D printing can be defined as the fabrication of objects t