Record breaker: trim-and-drill tool declared world's largest solid 3D printed structure

The 3D printed trim-and-drill tool, developed by researchers at the US Department of Energy’s Oak Ridge National Laboratory, took 30 hours to build using carbon fibre and ABS thermoplastic composite materials.

The 17.5’ long, 5.5’ wide and 1.5’ tall structure will now be tested in building the Boeing 777X passenger jet.

“The existing, more expensive metallic tooling option we currently use comes from a supplier and typically takes three months to manufacture using conventional techniques,” said Leo Christodoulou, Boeing’s director of structures and materials. “Additively manufactured tools, such as the 777X wing trim tool, will save energy, time, labour and production cost and are part of our overall strategy to apply 3D printing technology in key production areas.”

During an awards ceremony held at DOE’s Manufacturing Demonstration Facility at ORNL, where the 1,650lb component was 3D printed on the lab’s Big Area Additive Manufacturing machine, Guinness World Records judge Michael Empric measured the trim tool, proved it exceeded the required minimum of 10.6 cubic feet and announced the new record title.