Additive Layer Manufacturing Case Study

VALUE ENGINEERING IN APPLICATION OF ADDITIVE LAYER MANUFACTURING

SCOPE

Assystem Technologies worked in collaboration with a major aerospace OEM client on the application and implementation of additive layer manufacturing.

Our client needed to develop a variant of its aircraft for Trans-Atlantic operations to increase the aircraft’s range. In order to achieve this, a 97 tonne maximum take-off weight (MTOW) was required.

Our client needed to reduce component weight without compromising integrity, whilst also reducing cost. Assystem Technologies partnered with Renishaw to achieve this through additive layer manufacturing.

SERVICES

The trailing edge riblet was selected as a candidate for the value engineering exercise as the component is relatively simple to redesign for additive manufacturing.

  • Significant weight reduction of riblet achieved, (40‐50% than original component).
  • The part model was loaded into intelligent software packages to remove material where it is not required or structurally integral.
  • The shape was modelled into a smooth organic design before being built into a fully toleranced CATIA model.
  • The final design was optimised for manufacture with the addition of supports and consideration given to angular constraints.
  • The part was then built on the Renishaw AM250 additive manufacturing system.

Through our application of additive layer manufacturing, we were able to achieve the weight reduction required without impacting the component’s integrity.

CUSTOMER BENEFITS

  • Cost saving compared to original manufacturing process
  • Production lead time reduced