Download PDF
Simulation, 3D Printing, and Casting: A Symbiotic Solution for Large Aerospace Structures
Technology Category
- Analytics & Modeling - Digital Twin / Simulation
Applicable Industries
- Aerospace
- Equipment & Machinery
Applicable Functions
- Maintenance
- Product Research & Development
Use Cases
- Additive Manufacturing
- Manufacturing Process Simulation
Services
- System Integration
- Testing & Certification
The Challenge
The aerospace industry is constantly seeking ways to reduce mass and fuel consumption, and additive manufacturing, or 3D printing, offers significant potential in this regard. However, the technology is relatively new in aeronautics and faces certification and qualification issues. Additionally, the size of 3D printing machines limits their use for larger components, such as an airplane door. The challenge was to design an aircraft access door using a combination of additive manufacturing and casting methods. The door, due to its size and complexity, presented a promising opportunity for cost reduction through a one-shot production method. However, the door was too large to be feasible using Direct Metal Laser Sintering (DMLS), it was made of AS7G06 aluminum which is not yet qualified in aeronautics using DMLS, and it had a very thin skin with very tight dimensional and geometrical tolerances.
About The Customer
SOGECLAIR aerospace, part of the SOGECLAIR S.A. group, is a major engineering partner and prime contractor for the aerospace industry. The company offers consultancy and management services in configuration management, aero structures, systems installation, aircraft interiors, manufacturing engineering, and equipment. Its activities extend from the research and development phase to the supply of products. SOGECLAIR aerospace also offers production services through its subsidiaries and joint ventures: AviaComp, ADM, MSB, and PrintSky. The parts produced include fuel tank access doors using CFRP for the Airbus A350 and Bombardier C-Series, metallic floor structure for the Airbus A380 and business jet cabin interiors.
The Solution
Engineers from Sogeclair aerospace developed a process that combined additive manufacturing and casting to create the airplane door. They used Altair's HyperWorks software suite for design and optimization. The manufacturing process was based on investment casting from a 3D printed resin pattern. The engineers followed a systematic roadmap to ensure all project requirements were met. They used topology optimization in the concept phase of the design process to optimize the material layout within a given design space. Subsequent Finite Element (FE) analysis investigated the optimized design. Filling and solidification simulations were run to predict the position and size of defects such as incomplete filling areas or air bubbles. Feasibility samples were made for representative areas of the aircraft access door, especially the trickier ones. The door was then manufactured at real scale, 3D printed in PMMA resin using binder jetting technology, and cast and heat treated after removal from the mold.
Operational Impact
Quantitative Benefit
Related Case Studies.
Case Study
Smart Water Filtration Systems
Before working with Ayla Networks, Ozner was already using cloud connectivity to identify and solve water-filtration system malfunctions as well as to monitor filter cartridges for replacements.But, in June 2015, Ozner executives talked with Ayla about how the company might further improve its water systems with IoT technology. They liked what they heard from Ayla, but the executives needed to be sure that Ayla’s Agile IoT Platform provided the security and reliability Ozner required.
Case Study
IoT enabled Fleet Management with MindSphere
In view of growing competition, Gämmerler had a strong need to remain competitive via process optimization, reliability and gentle handling of printed products, even at highest press speeds. In addition, a digitalization initiative also included developing a key differentiation via data-driven services offers.
Case Study
Predictive Maintenance for Industrial Chillers
For global leaders in the industrial chiller manufacturing, reliability of the entire production process is of the utmost importance. Chillers are refrigeration systems that produce ice water to provide cooling for a process or industrial application. One of those leaders sought a way to respond to asset performance issues, even before they occur. The intelligence to guarantee maximum reliability of cooling devices is embedded (pre-alarming). A pre-alarming phase means that the cooling device still works, but symptoms may appear, telling manufacturers that a failure is likely to occur in the near future. Chillers who are not internet connected at that moment, provide little insight in this pre-alarming phase.
Case Study
Premium Appliance Producer Innovates with Internet of Everything
Sub-Zero faced the largest product launch in the company’s history:It wanted to launch 60 new products as scheduled while simultaneously opening a new “greenfield” production facility, yet still adhering to stringent quality requirements and manage issues from new supply-chain partners. A the same time, it wanted to increase staff productivity time and collaboration while reducing travel and costs.
Case Study
Integration of PLC with IoT for Bosch Rexroth
The application arises from the need to monitor and anticipate the problems of one or more machines managed by a PLC. These problems, often resulting from the accumulation over time of small discrepancies, require, when they occur, ex post technical operations maintenance.
Case Study
Airbus Soars with Wearable Technology
Building an Airbus aircraft involves complex manufacturing processes consisting of thousands of moving parts. Speed and accuracy are critical to business and competitive advantage. Improvements in both would have high impact on Airbus’ bottom line. Airbus wanted to help operators reduce the complexity of assembling cabin seats and decrease the time required to complete this task.
