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空中客车firm Satair delivers certified metal printed flying spare part

空中客车飞机零件的子公司和全球供应商,Satair它为美国航空公司的客户提供了声称的“首次认证的金属印刷飞行备件”。

Satair developed the 3D printed A320ceo wingtip fences after the part became unobtainable from the original supplier, who had difficulties providing the cast part. Additive manufacturing was selected as the alternate manufacturing method as a result of competitive cost and lead-time factors, in addition to increasing the flexibility of part production.

“We received an order for replacement parts and our AOG procurement department turned to the additive manufacturing team for a solution,” said Felix Hammerschmidt, HO Additive Manufacturing at Satair. “After a short pre-assessment, the part was handed over to the RapidSpares design offices at Airbus.

“使用新的认证流程,他们能够在五周内重新认证前铸件的一部分,并将其改编为钛,这是一种合格的AIRWorthy添加剂制造材料。”雷电竞充值

The first certified metal printed flying spare part for A320ceo by Satair. Image via Airbus.

3D printing spare parts for aerospace

Although Satair’s A320ceo wingtip fences may be the first certified metal printed flying spare part, elsewhere in the aerospace sector 3D printing has been utilized for some time in the design and manufacture of prototypes and functional parts.

Earlier this year,Additive Flight Solutions(AFS), a joint venture between 3D printer manufacturerStratasys和新加坡飞机专家SIA工程公司(SIAEC),received AS9100D Certificationfor its 3D printed aerospace parts. Stratasys’ 3D printers have also been leveraged by other firms in this area, including UK-based global engineering firmGKN Aerospacetoreduce its production times, alongside aerospace specialistIDECand prototyping service providerWehl & Partner, who used a Stratasys 3D printer to削减成本和材料浪费involved with composite molding.

In January, American multinational aerospace giant波音completed the first flight of its 777X jet, powered by twin GE9X engines fromGE Additivewhich are equipped withover 300 3D printed parts. The new set of airplanes is expected to enter service in 2021.

空中客车itself is no stranger to 3D printing, having also previously worked with Stratasys and Farsoon Technologies,making 3D printed plastics for civil aviation. Earlier this year, Airbus initiated a large-scale manufacturing project with researchers from the谢菲尔德大学高级制造研究中心(AMRC)。研究人员使用了Formlabs’3D打印技术produce 500 drilling caps在两天内,将常规交货时间降低了数周。

Prior to this, Australian metal 3D printer manufacturerTitomic收到一个Purchase Order for a Statement of Workfrom Airbus, concerning near-net demonstrator parts for a targeted application 3D printed using the firm’sTitomic Kinetic Fusion(TKF) additive manufacturing technology.

Additive manufacturing takes flight with 3D printed bracketing for the Airbus A350, manufactured by Stratasys Direct Manufacturing with FDM Technology and ULTEM™ 9085 resin.
Additive manufacturing takes flight with 3D printed bracketing for the Airbus A350, manufactured by Stratasys Direct Manufacturing with FDM Technology and ULTEM™ 9085 resin.

3D printing the A320ceo wingtip fences

Satair的A320Ceo机翼围栏安装在四个不同的版本中。右舷,端口,上部和下部,这四个部分称为船舶。机翼的印刷是在空客菲尔顿(Airbus Filton)的参考制造商店进行的,该商店去年是合格的,其中一台船只的建造工作需要26小时。

印刷后,这些零件需要各种后处理步骤才能成为行动性,并获得EASA表格1认证批准。第一艘船集于今年早些时候运送到航空公司,使其成为第一位带有空中客车金属3D印刷备件的操作员。

Compared to the conventional manufacturing process of the part, non-recurring costs were reduced by 45%, making it a far more cost-effective solution for customers, and with a significantly shortened lead time. This tailored 3D printing solution also reduces the likelihood of an AOG (Aircraft on the Ground) for this specific airplane.

“Satair is leading the way in providing additive manufactured parts for the aviation aftermarket and we currently have more than 300 part numbers certified for the technology covering every Airbus aircraft famil type including tools and Ground Support Equipment,” said Bart Jeijnen, CEO of Satair. “With more than 7,000 A320ceo Family aircraft in service worldwide, the demand for this specific additive manufactured part is likely to increase and with this Additive Manufacturing supply chain now in place, we will be able to produce these parts within a shorter lead time.

“Four more customers have already requested that same part following this successful delivery.”

Reijnen added that Satair had identified other titanium parts for which 3D printing could become a “more economical” way of production, citing higher flexibility and shorter lead times.

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Featured image shows the tailored additive manufactured solution reduces the likelihood of an AOG for this specific aircraft. Image via Airbus.