1. Additive Manufacturing in the Aerospace Industry
LAD INDUSTRIES:
By: Aziem Rujub
SATC 09/07/2019
Additive Manufacturing in the Aerospace Industry
Started in February 2017
Started in the maritime field.
Decided to pivot from a product based company into a capability based company.
Looking at the additive manufacturing industry.

2. AIM: Why: What: How: Localise value add especially manufacturing.
Awareness of the potential for AM locally.
How:
Expound through examples how AM can add value across the value chain.

3. Subtractive vs. Additive

4. Variations in AM Processes

5. AM Processes VAT Photo-Polymerisation Sheet Lamination
Material Jetting
Binder Jetting
Material Extrusion
Powder Bed Fusion
Direct Energy Deposition

6. Material Options Metals: Polymers: Composites: Titanium Aluminium
Stainless Steel
Tool Steel
Polymers:
ABS
ULTEM 9085
PEEK
PEKK
Nylon
Onyx
Composites:
Fibre Glass
Kevlar
Carbon Fibre

7. Value Proposition Reduced lead Times Complexity is Free
Part Consolidation
Weight Reduction
Cost Reduction

8. AM Evolution HIGH PRODUCT EVOLUTION NO SUPPLY CHAIN EVOLUTION
Path 3: Product Evolution
Design parts to obtain AM benefits.
Path 4: Business Model Evolution
Companies alter both supply chains and products in pursuit of new business models.
Path 1: Stasis
Replace old manufacturing techniques with AM.
Path 2: Supply Chain Evolution
Making parts closer to where they are needed.
NO SUPPLY CHAIN EVOLUTION
HIGH SUPPLY CHAIN EVOLUTION
Currently SA in on path 1, we need to be on path 4.
Industry 4.0.
Aircraft flying from London to JHB South Africa uses sensors and data analytics to determine that one of the fuel pumps is at 50% efficiency, the onboard computer triggers a blockchain order to its destination, in this case, a 3d printer based in Johannesburg. Once the plane lands, the part is already printed and delivered to a technician who uses VR glasses to replace the fuel pump, no special expertise needed.
This is the future and this is where we want to play!
NO PRODUCT EVOLUTION

9. Aerospace Value Chain

10. Design AM synonymous with rapid prototyping.
Possibility to evaluate concepts against each other.
Real hand feel and visualisation.
Potential for previously unachievable concepts.

11. Development Scope to disrupt product development: Complexity
Design for Performance/ Optimisation
Part Count Reduction
Shortened development cycle
Decreased cost

12. Denel Dynamics Boat-Tail
Printed by CSIR
Originally 30+ parts Machined/ bent and welded together.
30+ parts consolidated to 1 part.
48% reduction from 2.32 kg to 1.2 kg
40% cost savings.
Development time savings.

13. Development Challenge: Size
Maximum bed size: Aeroswift (2 x 0.6 x 0.6 m)
Maximum Volume: GE (1.1 x 1.1 x 0.3 m)

14. Manufacturing Tooling
Production
Manufacturing Tooling
End Items
Assembly
Composite Tooling
GE LEAP Engine Nozzle
Hand Tools
Manufacturing Jigs & Fixtures
GE Turboprop Engine – Catalyst
(1/3 of Parts AM – 855 parts to 12)
Assembly Jigs & Fixtures
Surrogates
Norsk (Titanium AM part using RPD)

15. GE LEAP fuel nozzle 30 000+ fuel nozzles printed.
2015 – 1 printer | 2018 – 40 printers.
20 parts consolidated to 1 part.
25% weight savings.
30% cost savings.
95% inventory reduction.
80% development time savings.
5 times more durable.
No nuts, bolts, welds and braces.

16. Production Challenge:
55% of aviation failures are due fatigue.
Powder Bed Fusion Methods result in:
Porosity.
Low Impact Strength
Porosity and lack of fusion result in an unusuable part in the Aerospace industry due to high life cycle fatigue.
This is true for other industries where the part is used structurally.

17. Production Solution Post Production Processing Heat Treatment.
Hot Isostatic Pressing (Shown to improve fatigue performance)
Quality Control Process (BEAM IT)
FAA aware of challenges but adopting a 7 year road map

18. Utilisation Operator/ Airline activity
Air New Zealand printing trays on demand.
Etihad partnering with Stratasys
Lufthansa Tehnik partnering with Oerlikon
Scope:
Customisation of interiors
Reduced Inventory

19. Maintenance Typically performed by MRO AM Scope:
Reproduce Legacy/ Obsolete Parts
Reduce Inventory
Manufacture at location
Tools
Small batch design updates

20. Conclusion
Additive Manufacturing has various value propositions worth considering.
There is potential for AM to impact the Aerospace value chain at almost all levels.
Localisation of manufacturing possible but needs to be evaluated on a case by case basis.

21. QUESTIONS?