Mar 28, 2016 | By Kira
When it comes to historic aircrafts and aircraft reproductions, there are your aviation fans and enthusiasts…and then, there is Dr. Christoph Vernaleken, a German physicist, doctor of engineering, and authority on nearly all things aircraft related. In particular, Vernaleken has become an expert on the Junkers Ju 388 L, a high altitude reconnaissance plane from World War II.
An extremely rare specimen, the last surviving Ju 88 is currently stored in the non-public area of the Smithsonian’s National Air and Space Museum, also known as Silver Hill. However, that hasn’t stopped Vernaleken from creating an entire website in its honor, and even publishing a book, both in German and in English, about the Junkers Ju 388 alongside friend and co-author Martin Handig.
Now, Vernaleken is set to embark on a new mission to bring the Ju 388 to life. Using CAD design and 3D printing technology, he wants to reproduce an accurate and museum-quality cockpit of this outstanding, 1943 German warbird, complete with flight instruments and actual simulation equipment.
With the first scale-model parts already 3D printed and a feasibility study in the works, the 3D printed Ju 388 Project is officially underway and could eventually become the most accurate way for the public to explore and learn about the Ju 388 for themselves.
Historic image of the Ju 388 WWII aircraft
Vernaleken’s fascination with historic aircrafts began in the early 1980s, when he visited the world’s largest museum of science and technology, Munich’s Deutsches Museum. After graduating, he worked for seven years as an aviation safety and flight deck researcher at TU Darmstadt before joining Airbus Defense in the Human Factors Engineering and Flight Deck departments.
In 1993, he had the opportunity to film the interior of the last remaining Ju 388, which, luckily, is still in excellent condition. Inspired by this footage, he made the long-term goal of one day reconstructing the Ju 388’s cockpit panels. Years later, in 2013, Vernaleken became familiar with 3D printing, and realized that through this cost-effective, technically accurate manufacturing method, he could finally realize that goal.
Current state of the Ju 388 cockpit
“Of course, static reproductions of instrument panels are fascinating in their own right, but for a professional systems engineer working in the field of Human Factors Engineering, a dynamic simulation of cockpit procedures is way more attractive,” explained the physicist.
His biggest initial challenge was to acquire either original instruments or suitable drawings of the aircraft’s cockpit to create accurate 3D models. Indeed, accuracy is paramount, since even a few tenths of a millimetre of error could render the spare part unusable, however Vernaleken's years of expertise and incredible eye for detail have made him more than ready for the job.
“Until recently, the only possibility to reproduce instrument casings consisted in the various second cast techniques, resulting in (partial) epoxy resin casts,” he said. However, with 3D CAD software (he uses Punch! ViaCAD Pro 9) and “sufficient patience” one can “create a 3D model of the instrument casting to be reproduced in several hours, ideally during dark winter evenings.”
Once satisfied with the digital reproduction, Vernaleken sends his 3D model to 3D printing service i.materialise. Test prints are ordered in low-cost, laser-sintered polyamide, however for the final, museum-quality replica, he relies on i.materialise’s Prime Gray. Though more expensive, he explains that Prime Gray has a similar density and results in an “optical quality almost equal to that of injection molding.”
As the image below shows, the aged original piece in the background is nearly identical to its 3D printed counterpart, giving “an impressive demonstration of the current capabilities of 3D printing.”
Even with the slightly more expensive materials, Vernaleken revealed that 3D printing is still by far the most cost-effective way to create reproductions of cockpit parts that were originally cast in metal or created from historic plastic materials. “Unit costs would be astronomically high if molds for casting metal or plastic injection molding would have to be manufactured in the classic fashion,” he said. “[3D printing] is a key enabler.”
Currently, Vernaleken has released some of his historic aircraft component replicas to his i.materialise profile. These include a 3D printed Bakelite bezel of a cockpit switch panel and metal starter handles for the Lutwaffe aircraft.
However, before the Ju 388 Project can begin in earnest, he is conducting a feasibility study. The first objective of this study is to find out whether it is possible in principle to create museum-quality and full-scale spare parts for historic cockpit instruments using 3D printing and other advanced manufacturing techniques. The second objective will be to see whether he can also find a cost-effective way of making these simulations for the warbird home cockpit/simulator market.
Once complete, the 3D printed Ju 388 cockpit replica will be an unparalleled resource, allowing aviation enthusiasts, students and history buffs to explore and learn about this rare WWII aircraft without compromising the original, safely stored specimen, and is yet another excellent example of how the most of modern technologies can help bring history to life.
Posted in 3D Printing Application
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