Metal laser melting technology will play an important role in aircraft manufacturing
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This trend is even more evident nowadays: the outstanding performance of this technology in aircraft "lightweight construction" and "bionics": metal laser additive manufacturing technology is changing its design thinking. In the future of aircraft design, the components will be able to specifically absorb the force line. At the same time, it meets the lightweight requirements. Durable, save resources and improve the cost structure, so that you can have both fish and bear's paw.
Mr. Frank Herzog, Founder and CEO of ConceptLaser GmbH, Mr. Peter Sander, Head of Emerging Technologies and Concepts, Hamburg Airbus, and Professor Claus Emmelmann, CEO of LaserZentrum Nord GmbH (Engineering Ph.D.), participated in the connectors used on the Airbus A350XWB, R & D and production of brackets 3D metal printing project. Previously, the part was machined from aluminum. Now, you can print with titanium material, weight loss rate greater than 30%.
Airbus A350XWB connectors are manufactured using 3D printing and were finalists for the 2014 German Economic Innovation Awards 2014 in 2014. The jury's assessment is that such a cross-sectoral development has completely changed the way aircraft components are manufactured and the "lightweight" approach to civil aircraft. In December 2015, the three members participating in the project were honored with the "Best Team" in the "German Future Award 2015" held in Berlin, Germany and accepted the honor certificate personally presented by the German president.
The argument that supports the use of metal laser melting technology in the aircraft industry is freedom of forming and weight reduction. Among them, the "lightweight" feature can effectively help airlines achieve more economical operation in aircraft operations. The weight reduction that can be achieved with fixed elements (brackets) will help to achieve lower fuel consumption or increase the loading capacity of the aircraft.
Thousands of small-scale FTI (Flight Test Installation) brackets are required to design a new aircraft. The LayerManufacturing method not only allows designers to quickly produce new designs, but also produces parts that weigh more than 30% lighter than conventional castings or milled parts.
In addition, the metal laser additive manufacturing process is based directly on CAD data, eliminating the need for molds, reducing costs and allowing parts to be used faster, saving up to 75% of the time. At the same time, the use of the characteristics of the process without mold, early in the prototype can be produced with the characteristics of parts close to mass production, which greatly saves mold costs.
Aircraft parts produce up to 95% recyclable waste during milling. With laser melting technology, operators get not only "parts close to the final profile" but only about 5% scrap. "In the aircraft manufacturing industry, we call it the 'buytoflyratio', 90% of which is a remarkable value here, which is of course a positive side when it comes to measuring energy efficiency." Professor Claus Emmmann (PhD) said. This is especially attractive when applied to advanced and expensive aircraft-building materials like titanium.