Increase success rates through optimized concepts and proposals, and know how to deliver it.
In recent years, modern Additive Manufacturing has grown exponentially in terms of what can be achieved. No longer just a method to produce nice-looking prototypes, now engineers can create any shape that best meets their need and can manufacture them almost anywhere they are needed: under the sea, in deep space, in crisis zones or on the shop floor.
While additive manufacturing is hardly new to aviation companies, there is a new push to get it from the laboratory to the factory floor. GE Aviation is working on entirely 3D printed engines. CFM’s LEAP engine has 3D printed fuel nozzles. In April, Reuters reported that Boeing would start using 3D printed parts for structural components of its 787 Dreamliner.
Additive manufacturing can accelerate the innovation process, eliminate the need for molds, reduce raw material and energy used in production by 90 percent and reduce fuel costs for airlines. So how can Aerospace companies embrace additive manufacturing ahead of their competition?
The Benefits of Additive Manufacturing
Engineers focused on Additive Manufacturing (AM) challenges must solve these questions:
- Can we make the structure 50% lighter and 50% stronger at the same time?
- Can we print spare parts with in-service quality?
- How many parts can we print per hour if they need to exhibit a specific strength?
- Can we achieve durability?
- How can we design AM to go from single parts to full assembly?
Additive Manufacturing allows engineers to optimize standard parts for cost and weight, prototype and produce complex parts quickly and cheaply without tooling. AM cuts material waste compared to traditional milling methods. Engineers leverage the 3DEXPERIENCE platform to design and simulate highly optimized parts based on space allocation, loads, constraints, manufacturing processes, and multi material requirements (polymers, metals, and engineered materials) and then use various 3D printers to produce these optimized parts.
Additive manufacturing makes it possible to combine multiple and numerous parts or Bill of Materials (BOMs) into one, resulting in big savings by reducing assembly, labor, inventory and maintenance, as well as potentially reducing certification paperwork. AM also produces a highly complex shape that reduces material and weight by 40% to 90%. AM reduces between 80 and 90 percent of scrap while associated with machining or other subtractive manufacturing steps.