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Additive Manufacturing
General Electric is making a radical departure from the way it has traditionally manufactured things. Its aviation division, the world’s largest supplier of jet engines, is preparing to produce a fuel nozzle for a new aircraft engine by printing the part with lasers rather than casting and welding the metal. The technique, known as additive manufacturing (because it builds an object by adding ultrathin layers of material one by one), could transform how GE designs and makes many of the complex parts that go into everything from gas turbines to ultrasound machines.
Additive manufacturing—the industrial version of 3-D printing—is already used to make some niche items, such as medical implants, and to produce plastic prototypes for engineers and designers. But the decision to mass-produce a critical metal-alloy part to be used in thousands of jet engines is a significant milestone for the technology. And while 3-D printing for consumers and small entrepreneurs has received a great deal of publicity, it is in manufacturing where the technology could have its most significant commercial impact (see “The Difference Between Makers and Manufacturers,” January/February 2013).
Last fall, GE purchased a pair of companies with know-how in automated precision manufacturing of metals and then folded the technology into the operations of GE Aviation. That group doesn’t have much time to demonstrate that its new technology can work at scale. CFM International, GE’s joint venture with France’s Snecma, will use the 3-D-printed nozzles in its LEAP jet engine, due to go into planes in late 2015 or early 2016 (CFM says it already has commitments of $22 billion). Each engine will use 10 to 20 nozzles; GE needs to make 25,000 of the nozzles annually within three years.
GE chose the additive process for manufacturing the nozzles because it uses less material than conventional techniques. That reduces GE’s production costs and, because it makes the parts lighter, yields significant fuel savings for airlines. Conventional techniques would require welding about 20 small pieces together, a labor-intensive process in which a high percentage of the material ends up being scrapped. Instead, the part will be built from a bed of cobalt-chromium powder. A computer-controlled laser shoots pinpoint beams onto the bed to melt the metal alloy in the desired areas, creating 20-micrometer-thick layers one by one. The process is a faster way to make complex shapes because the machines can run around the clock. And additive manufacturing in general conserves material because the printer can handle shapes that eliminate unnecessary bulk and create them without the typical waste.
The rest of GE—together with its competitors—is watching closely. GE Power & Water, which makes large gas and wind turbines, has already identified parts it can make with the additive process, and GE Healthcare has developed a method to print transducers, the expensive ceramic probes used in ultrasound machines. “It’s really fundamentally changing the way we think about the company,” says Mark Little, GE’s chief technology officer.
Breaking with traditional manufacturing techniques, such as casting and machining material, gives GE product designers far greater flexibility. Additive manufacturing machines work directly from a computer model, so people can devise completely new shapes without regard for existing manufacturing limitations. “We can make configurations that we just couldn’t before,” Little says.
GE engineers are starting to explore how to use additive manufacturing with a wider range of metal alloys, including some materials specifically designed for 3-D printing. GE Aviation, for one, is looking to use titanium, aluminum, and nickel-chromium alloys. A single part could be made of multiple alloys, letting designers tailor its material characteristics in a way that’s not possible with casting. A blade for an engine or turbine, for example, could be made with different materials so that one end is optimized for strength and the other for heat resistance.
All that is still on paper—or rather, in the computerized designs of product engineers. For now, GE’s engine nozzle—a part small enough to fit in the palm of your hand—will be the first big test of whether additive manufacturing can revolutionize the way complex high-performance products are made.
Source: http://www.technologyreview.com/featuredstory/513716/additive-manufacturing/
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Founded by Russian entrepreneur Dmitry Itskov in February 2011 with the participation of leading Russian specialists in the field of neural interfaces, robotics, artificial organs and systems.
The main goals of the 2045 Initiative: the creation and realization of a new strategy for the development of humanity which meets global civilization challenges; the creation of optimale conditions promoting the spiritual enlightenment of humanity; and the realization of a new futuristic reality based on 5 principles: high spirituality, high culture, high ethics, high science and high technologies.
The main science mega-project of the 2045 Initiative aims to create technologies enabling the transfer of a individual’s personality to a more advanced non-biological carrier, and extending life, including to the point of immortality. We devote particular attention to enabling the fullest possible dialogue between the world’s major spiritual traditions, science and society.
A large-scale transformation of humanity, comparable to some of the major spiritual and sci-tech revolutions in history, will require a new strategy. We believe this to be necessary to overcome existing crises, which threaten our planetary habitat and the continued existence of humanity as a species. With the 2045 Initiative, we hope to realize a new strategy for humanity's development, and in so doing, create a more productive, fulfilling, and satisfying future.
The "2045" team is working towards creating an international research center where leading scientists will be engaged in research and development in the fields of anthropomorphic robotics, living systems modeling and brain and consciousness modeling with the goal of transferring one’s individual consciousness to an artificial carrier and achieving cybernetic immortality.
An annual congress "The Global Future 2045" is organized by the Initiative to give platform for discussing mankind's evolutionary strategy based on technologies of cybernetic immortality as well as the possible impact of such technologies on global society, politics and economies of the future.
Future prospects of "2045" Initiative for society
2015-2020
The emergence and widespread use of affordable android "avatars" controlled by a "brain-computer" interface. Coupled with related technologies “avatars’ will give people a number of new features: ability to work in dangerous environments, perform rescue operations, travel in extreme situations etc.
Avatar components will be used in medicine for the rehabilitation of fully or partially disabled patients giving them prosthetic limbs or recover lost senses.
2020-2025
Creation of an autonomous life-support system for the human brain linked to a robot, ‘avatar’, will save people whose body is completely worn out or irreversibly damaged. Any patient with an intact brain will be able to return to a fully functioning bodily life. Such technologies will greatly enlarge the possibility of hybrid bio-electronic devices, thus creating a new IT revolution and will make all kinds of superimpositions of electronic and biological systems possible.
2030-2035
Creation of a computer model of the brain and human consciousness with the subsequent development of means to transfer individual consciousness onto an artificial carrier. This development will profoundly change the world, it will not only give everyone the possibility of cybernetic immortality but will also create a friendly artificial intelligence, expand human capabilities and provide opportunities for ordinary people to restore or modify their own brain multiple times. The final result at this stage can be a real revolution in the understanding of human nature that will completely change the human and technical prospects for humanity.
2045
This is the time when substance-independent minds will receive new bodies with capacities far exceeding those of ordinary humans. A new era for humanity will arrive! Changes will occur in all spheres of human activity – energy generation, transportation, politics, medicine, psychology, sciences, and so on.
Today it is hard to imagine a future when bodies consisting of nanorobots will become affordable and capable of taking any form. It is also hard to imagine body holograms featuring controlled matter. One thing is clear however: humanity, for the first time in its history, will make a fully managed evolutionary transition and eventually become a new species. Moreover, prerequisites for a large-scale expansion into outer space will be created as well.
Key elements of the project in the future
• International social movement
• social network immortal.me
• charitable foundation "Global Future 2045" (Foundation 2045)
• scientific research centre "Immortality"
• business incubator
• University of "Immortality"
• annual award for contribution to the realization of the project of "Immortality”.
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