Additive manufacturing a powerful tool for the aerospace industry

Abstract

Purpose Additive manufacturing (AM) offers potential solutions when conventional manufacturing reaches its technological limits. These include a high degree of design freedom, lightweight design, functional integration and rapid prototyping. In this paper, the authors show how AM can be implemented not only for prototyping but also production using different optimization approaches in design including topology optimization, support optimization and selection of part orientation and part consolidation. This paper aims to present how AM can reduce the production cost of complex components such as jet engine air manifold by optimizing the design. This case study also identifies a detailed feasibility analysis of the cost model for an air manifold of an Airbus jet engine using various strategies, such as computer numerical control machining, printing with standard support structures and support optimization. Design/methodology/approach Parameters that affect the production price of the air manifold such as machining, printing (process), feedstock, labor and post-processing costs were calculated and compared to find the best manufacturing strategy. Findings Results showed that AM can solve a range of problems and improve production by customization, rapid prototyping and geometrical freedom. This case study showed that 49%–58% of the cost is related to pre- and post-processing when using laser-based powder bed fusion to produce the air manifold. However, the cost of pre- and post-processing when using machining is 32%–35% of the total production costs. The results of this research can assist successful enterprises, such as aerospace, automotive and medical, in successfully turning toward AM technology. Originality/value Important factors such as validity, feasibility and limitations, pre-processing and monitoring, are discussed to show how a process chain can be controlled and run efficiently. Reproducibility of the process chain is debated to ensure the quality of mass production lines. Post-processing and qualification of the AM parts are also discussed to show how to satisfy the demands on standards (for surface quality and dimensional accuracy), safety, quality and certification. The original contribution of this paper is identifying the main production costs of complex components using both conventional and AM.

Diffraction-Based Residual Stress Characterization in Laser Additive Manufacturing of Metals

“…In essence, an energy source incrementally manufactures a part in a layer-by-layer process from a wire or powder feedstock [2]. AM processes allow the fabrication of complex structures, which cannot be produced via conventional manufacturing methods [3,4]. This freedom of design enables improvements in component performance and weight reduction of parts [4,5].…”

“…AM processes allow the fabrication of complex structures, which cannot be produced via conventional manufacturing methods [3,4]. This freedom of design enables improvements in component performance and weight reduction of parts [4,5]. In addition, the rapid solidification rates and tailored heat treatment schedules can improve certain material properties, leading to further performance and efficiency gains [6][7][8][9].…”

A Voxel-Based Watermarking Scheme for Additive Manufacturing

“…Additive manufacturing (AM) techniques have been widely used in scientific, engineering, medical, and other applications [1][2][3]. An AM process is composed of three stages: geometrical modelling, G-code generation, and 3D printing [2,3].…”

“…Additive manufacturing (AM) techniques have been widely used in scientific, engineering, medical, and other applications [1][2][3]. An AM process is composed of three stages: geometrical modelling, G-code generation, and 3D printing [2,3]. The resultant geometric models, G-code programs, and physical objects consume valuable resources, including human efforts, computing costs, energies, and raw materials.…”

“…In most of the published watermarking algorithms, the digital models are presumed to be expressed in polygonal representations, for example, stereolithography (STL) and OBJ formats [2][3][4][5]. However, tissues and organs, segmented from 3D medical image data, are composed of voxels [15].…”