3D Printing for Aviation

Additive Manufacturing for Engine, Turbine Parts and more

Want to manufacture functional parts with complex geometries and defined aerodynamic properties cost-effectively and as quickly as possible? Unthinkable? No.  
Engine and turbine parts are typical examples of what’s possible with industrial 3D printing, as well as parts for cabin interiors.

Functional integration, the development of increasingly complex designs and the parts that come with them are key drivers in the aerospace industry. Saving materials and weight, reduces both the fuel consumption and the CO₂ emissions. Today, these topics are more important than ever before. That’s why leading aerospace companies have long been integrating additive manufacturing technology when planning their production strategies for the future.

In close collaboration with leading companies from the aerospace sector, we have accomplished and accompanied many different success stories.

Our added value takes the form of a consistent solution: from the provision and implementation of 3D printing systems to individual consulting and support with qualified processes for materials, systems, parts or complete assemblies. This intensive collaboration is advancing the industry’s innovative strength. A few major market players are planning to additively manufacture significant sections of their aircraft’s interiors in the upcoming years.

At a Glance
Advantages of 3D Printing for Aviation

• Less Weight
  Industrial 3D printing can manufacture very strong and lightweight structures that achieve weight reductions of around 40-60 %. The effects: leaner cost structures, material savings and lower fuel consumption. 

• Functional Integration
  The process allows maximum functionality to be integrated into as few parts as possible. The advantages: assembly and quality assurance costs are reduced, and the vulnerabilities associated with assemblies of many different components are eliminated.

• More Flexible Production Planning
  The tool-free production process allows product adaptations to be implemented more quickly. Spare part storage can be significantly reduced by manufacturing on demand without an extended lead time. The cost advantages become strongly apparent over the long life cycles of aircraft.

• Industry-Compliant Materials & Strengths
  EOS systems process specialized materials for the aerospace industry. 3D printed parts meet industry-specific requirements to various safety-relevant hazard levels commonly used in aerospace. 

• Complex Parts
  Industrial 3D printing enables a wide range of design optimizations – from part customization and upgrades to exclusive innovations that can only be manufactured additively.

• Lower CO₂ Emissions
  More efficient engine, turbine and lightweight parts for interiors reduce the fuel consumption and hence the CO₂ emissions of aircraft.

• Significant Cost Reductions
  Additive manufacturing is a tool-free process. This means that significant cost savings can be achieved in comparison to conventional manufacturing processes.  

Manufacture Engine Parts for Aviation With Industrial 3D Printing

Constructing engines and turbines means mastering challenges such as optimizing volume, performance and environmental friendliness. In these areas, 3D printing can make a significant contribution. It allows engines with sophisticated geometries, defined aerodynamic and fluid dynamic properties to be produced, as well as lightweight structures whose individual parts weigh up to 60 % less. Processing superalloys is also more cost-effective with 3D printing, since the material usage rate is lower. The results: significantly reduced environmental pollution over the lifetime of the aircraft. Parts made from a single piece are also more resilient and less susceptible to damage. 

• Fast: development, manufacturing and delivery times are significantly reduced

• Flexible: very high design freedom

• Cost-efficient: low material and tool usage, drastically reduce development and manufacturing costs

• The EOS system supports comprehensive quality assurance, including online monitoring and optical tomography.

Liebherr

Parts for the Primary Flight Control of the Airbus A380

Liebherr Aerospace is a leading supplier of systems for the aviation industry. With more than fifty years of experience, the company develops, manufactures and maintains a variety of aircraft instruments, including flight control and actuation systems, landing gears, air management systems and gearboxes.

Using their metal 3D printer, the EOS M 400-4, Liebherr produced an innovative high-pressure hydraulic block for the Airbus A380. The new additively manufactured valve block achieves the same performance as the conventionally made part but is much lighter and contains fewer individual components. The part is made from a titanium alloy and satisfies all of the certification requirements needed for flight operations.

• -35 % weight reduction
• -10 individual parts functional integration

Etihad Engineering 
The Aircraft Cabin of the Future

Etihad Engineering is the largest service provider for aircraft maintenance, repair and operations (MRO) in the Middle East. As a subsidiary of the Etihad Aviation Group, the company offers around-the-clock maintenance services, including design, composite material repairs, cabin refitting and part-related services, in its modern facilities at Abu Dhabi International Airport. 
 

"Together with EOS, Etihad opened the first 3D printing manufacturing facility in the Middle East approved by the European Aviation Safety Agency (EASA) to design and manufacture aircraft parts."