Aerospace Solutions

ADDITIVE MANUFACTURING FOR AEROSPACE

Many complex parts are used in the engines and bodies of aircraft. Reducing overall operational costs is essential to be competitive in the aerospace industry.

We are AS9100 certified for the manufacture of aerospace parts and components, and are in a unique position to help provide solutions to engineering problems. Our Advanced Digital Manufacturing™ process starts with analyzing your requirements and functional specifications. Using Design for Additive Manufacturing (DfAM) methods, we optimize and potentially reduce the weight of parts, while consolidating formerly complicated assemblies into fewer components.

This can reduce serial production costs through materials savings and simplified assembly, and ultimately brings cost savings from less fuel consumption. The resulting design can then be manufactured using our metal additive manufacturing (AM) / 3D printing DMLS technology and post-processed with our heat treating and CNC machining capabilities.

AM is now being explored for unlocking its potential benefits in the aerospace industry, from civil to defense and space systems manufacturing. Applications range from new production to maintenance repair and overhaul (MRO). In the space industry, weight savings resulting from additive manufacturing can reduce launch costs of payload such as satellites.

YOUR DESIGN MANUFACTURED

1 YOUR IDEA

Think It.

You have a great idea, and whether you have CAD drawings ready, or a paper sketch of existing part modifications, we can help you bring that idea to reality.

2 OUR ENGINEERING DESIGN EXPERTISE

Prepare It.

There are many considerations that need to be addressed before geometry can be 3D printed in metal. Support structure strategies, build orientation, part consolidation for reduced weight, and more. All these are part of “Design for Additive Manufacturing” (DfAM) principles that our team of engineers can provide you.

3 ADDITIVE MANUFACTURING (3D PRINTING)

Print It.

Our Direct Metal Laser Sintering (DMLS) printers use a high power-density laser to melt and fuse metallic powders together to create devices and parts. We offer dedicated Cobalt Chrome and Titanium printers to our customers for regulated Aerospace and Medical applications.

4 POST-PROCESSING & FINISHING

Make It.

Parts are removed from the build plate and finished to your specifications. Polishing, sand-blasting, threading, and even mirror-finishing of metal parts is possible in this phase of production.

AEROSPACE APPLICATIONS

NON-STRUCTURAL/INTERIOR COMPONENTS

Non-structural aircraft components add significant weight to an aircraft. These may included overhead bin brackets, seat components, and food trolleys, lightweight, topology optimized components can reduce un-necessary weight. Additive manufacturing allow the designer to makes these parts reality.

TURBINE COMPONENTS

New generations of gas turbines are designed to run hotter, deliver more power, and be more efficient. Additive manufacturing enables the designer to create the complex internal cooling geometries needed to accomplish these goals. Opportunities also exist within older generation gas turbines to re-think their design, improve replacement part supply chains and reduce costs using additive manufacturing.

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SATELLITE SYSTEMS

Launching satellites is expensive and every ounce of weight savings is worth thousands of dollars. By designing parts for minimal weight, while maintaining maximum strength, the resultant geometries can be complex. Additive manufacturing makes these parts manufacturable.

HEAT EXCHANGERS

Many aircraft systems rely on complex heat exchangers. Conventionally manufacturing these complex components is extremely expensive. Additive manufacturing improves heat transfer by increasing the surface area by using complex internal channels and lattice structures. Further, these complex, single piece designs result in weight reduction, elimination of braze/weld joints and reduction in manufacturing cost.

FUEL DELIVERY SYSTEMS

Proper fuel flow, atomization and mixing is critical in gas turbine engines. The end result is increased power, reduced fuel consumption and reduced green house gas emissions. Additive manufacturing takes advantage of the complex geometry required to realize improved fuel deliver designs.

HYDRAULICS

Aircraft hydraulic system components are typically machined from blocks of material or cast into basic geometries. Control valves, pumps, or cylinders can be designed to take advantage of the benefits of additive manufacturing. Multi-piece components can be consolidated into a single, more efficient design, and sub-assembly part counts can be reduced saving weight and cost.

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NOT SURE WHERE TO START?

WE’RE HERE TO HELP

From the initial phase of a project, our engineering team can consult with you to help optimize your part or product to realize the full benefits of additive manufacturing. Whether your next step is 510k approval, or manufacturing planning for serial production, we have the experience you need to get to market laser fast.

We have invested in the listed software to allow us to consult on projects on a more advanced level. We have the simulation and optimization software needed to do research and development projects.

More importantly than investing in our technology, we have invested in the people who make our engineering consulting services come together. Our highly trained and experienced engineers are thought leaders in the additive manufacturing industry. From CAD modeling and engineering, all the way through manufacturing, get our engineering team working for you!

Altair HyperWorks DesktopsolidThinking Inspire and EvolveMaterialise 3-maticSTL
Altair HyperWorks Solvers – Optistruct & RADIOSSSolidWorks with Simulation PremiumMoldex3D
Altair SIMLABSiemens NXAcuSolve CFD Solutions
Interested in the benefits of Metal Additive Manufacturing? Let’s partner on your next project!