Windshield wipers may not seem particularly interesting; what is there to improve about them, anyway? They’re windshield wipers. They wipe windshields, and they’ve been wiping windshields for as long as cars, airplanes and helicopters have existed. They’re complicated little pieces of machinery, though, and no one can argue that they aren’t critical. I live in what’s known as the Snow Belt, so I’ve been driving in horrendous conditions since I got my license. Believe me, the design and quality of windshield wipers makes a huge difference. They’re even more vital for aircraft. While you can pull your car to the side of the road to clean off your windshield if necessary, that’s not exactly an option with a plane or helicopter. So your wipers better be good.
“These windshield wipers require a multitude of tests with regard to their functionality and serviceability, as well as their ease of installation and the future manufacturing process,” said Frank Singer, manager of engineering at Airbus Helicopters Deutschland GmbH.
Needless to say, such extensive testing can take a lot of time and money. The X400, however, greatly reduced the requirements for both. After a model was developed, the X400 was used to quickly print the gears, levers and shafts for the wipers; the threads, bearings and sleeves would be incorporated at a later time. With this process, Airbus was able to create prototype after prototype at minimal cost. Those functional prototypes could then be tested alongside the helicopter’s other components.
According to Singer, the benefits of 3D printing are not limited to cost effectiveness. In other manufacturing processes, a functional prototype cannot be produced nearly as early on as it can be with 3D printing. Such an early prototype allows for parts to be more quickly and easily tested, and for problems to be corrected much more efficiently. For Airbus, which manufactures helicopters for crucial military purposes, efficiency and thoroughness are of the utmost importance, and German RepRap was glad to help. Tell us your thoughts on this project in the German RepRap 3D Printed Windshield Wiper Prototypes forum over at 3DPB.com.