Challenges of manufacturing an layout optimised EB-PBF component for aerospace flight

challenges

The challenges for manufacturing AM components for critical aerospace applications are numerous, reducing the amount of innovation that can be applied to the industry. This presentation will describe the challenges that the MTC encountered during the EWIRA Clean Sky 2 project, which aimed to manufacture an aileron hinge bracket using electron beam powder bed fusion (EB-PBF) for a test flight. Challenges surrounding machine stability, sensitivity of the AM process and surface finishing of complex components will be discussed, with a view given on where the future state needs to focus.

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Development of Magnesium Laser Powder Bed Fusion to manufacture light-weight components for Aerospace applications

weight

Laser Based Powder Bed Fusion (LPBF) is an Additive Manufacturing (AM) process that offers great opportunities such as weight reduction and improved performance of metallic parts. These advantages are especially beneficial for aerospace applications. Several nickel superalloys are processed in LPBF for high-temperature applications.

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Increasing resource efficiency of aviation by innovative materials and bionic design for metal components made by additive manufacturing

design

Additive Manufacturing allows for unconventional design, for weight savings, for functional integrations and efficient production for small lot sizes. To move from simple polymer parts such as brackets to highly functional structural metal components, the productivity of the LB-PBF can be increased while making it more robust with Laser Beam Shaping.

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Next generation Design Software for 3D Printed Aerospace Components

software

The gap between the software and hardware capabilities in additive manufacturing poses an obstacle in taking full advantage of this disruptive manufacturing technology. We all know that 3D printed parts can reach unprecedented mechanical properties and heat efficiency, but now it is also possible to design these parts in a time efficient manner.

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Additive Manufacturing Innovation Trends in Aerospace

Alkaios Bournias Varotsis

by Alkaios Bournias Varotsis, Additive Manufacturing Consultant, Additivist

Aerospace was one of the first industries to embrace Additive Manufacturing. In recent years, we’ve seen companies adopt AM to both drive the design of new, high-efficiency components that are impossible to manufacture with other methods and to optimise the operational efficiencies of their MRO supply chains.

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