Industrial 3D printing of high-tech aerospace components

 

The cost-effective, tool-less production of lightweight components reduces fuel consumption, material costs and CO2 emissions

 

Engine and turbine parts as well as cabin interior components are typical applications for industrial 3D printing / Additive Manufacturing (AM. This is where the benefits of innovative EOS technology come to the fore: functional components with complex geometries and defined aerodynamic properties can be manufactured quickly and cost-effectively. Material and weight savings lower fuel consumption and CO2 emissions. Manufacturer-specific adaptations and small production runs are further arguments in favour of Additive Manufacturing technology. This is why leading aerospace companies have integrated AM into their planning of future production strategies.

 

Cost reduction: Since part production using Additive Manufacturing does not cause set-up and tooling costs, production costs are only incurred for the parts themselves, at the time they are manufactured. Even small production runs and one-off pieces do not cause added cost. In addition, system parts designed for optimum function can often be realized as a single part, simplifying assembly and quality assurance.

 

Lightweight design: Intelligent lightweight structures manufactured using laser sintering processes combine high strength with a weight reduction of 40–60%. The material savings translate into more flexibility in design and engineering. As a result, airplanes consume significantly less fuel and emit less carbon dioxide.

 

Toolless production: EOS industrial 3D printing technology enables maximum flexibility in production planning. In addition, toolless production processes require less energy and raw material than conventional manufacturing operations. Modified parts, upgrades and spare parts can be produced as needed, obviating the need for storage. Given the long service lives of airplanes, Additive Manufacturing processes yield clear cost benefits.