[ Additive Manufacturing ]
[ Additive Manufacturing ]
progress, step by step, from the A350 w-DED parts and into more critical applications on other programmes and other aircraft applications( including the wings and landing gear in the longer term).
DED R & T complex small-scale demonstrator
Bringing agility to aircraft development Traditional die forging also requires the creation of large, complex tooling that can take up to two years and require a large up-front capital investment. By contrast, a 3D-printed part’ s shape is determined by a computer programme, reducing the lead time to just a few weeks. w-DED’ s agility will be of immediate benefit to the successful and timely construction of the first development aircraft, especially while the final detailed component designs are being tweaked and optimised, right up to the point when the first aircraft starts to take physical shape.
First proof in A350 production Airbus recently started serial integration of the largest w-DED parts into the A350’ s Cargo Door Surround area. These particular Airbusdesigned parts for this exploratory phase were 3D-printed by a qualified supplier using plasma w-DED, ultrasonically inspected by Testia Bremen and finally machined and installed in Airbus factories. These parts are functionally and geometrically identical to the traditional forged components they replace, but they deliver immediate, real-world cost savings. Looking forward, the next aim is to
“ Designed for DED” Importantly, this technology enables a concept called“ designed for DED.” Instead of having engineers design a complex component as an assembly of several separate pieces that must be joined together, they can now design it as a single, intricate and optimised component that is printed all at once. This ability to merge multiple components into one will simplify the supply chain, reduce assembly labour, shorten cycle time and unlock the full potential of the next generation of 3D-designed airliners.
The race is on... Today, across Airbus and its partners, the race to develop experience with w-DED for critical parts is progressing well, with very promising results. Engineers are testing different energy sources, including plasma, arc welding, electron- and laser beam, while also assessing the“ Buy”( outsourcing the printing) and“ Make”( producing in-house) strategies. Furthermore, governed by an Airbus group level approach, the resulting technologies will become industry standards and be applicable throughout the company.
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