Forum Aviation

WEDNESDAY, 23 June 2021

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09:00 - 09:05

Welcome from the Rapid.Tech 3D Live-TV-Studio

Michael Kynast, Michael Eichmann und Prof. Gerd Witt | Messe Erfurt GmbH, Stratasys GmbH, Universität Duisburg-Essen

Michael Kynast, CEO Messe Erfurt GmbH
Michael Eichmann, Stratasys GmbH, Advisory Board Rapid.Tech 3D
Prof. Gerd Witt, Universität Duisburg-Essen, Lehrstuhl Fertigungstechnik, Advisory Board Rapid.Tech 3D

09:05 - 09:15

Welcome from the Rapid.Tech 3D Live-TV-Studio

09:15 - 09:45

The aerospace industry is characterized by small quantities, the highest safety requirements and, more than almost any other industry, by the need to save weight. Every reduced kilogram of weight saves up to 3 kg of CO2 - and that on a daily basis. Moreover, the short-term supply of spare parts is quite challenging. That is why aerospace industry is ideal for the introduction of components that are topologically optimized and manufactured by 3D printing processes. For more than 10 years, parts have been converted from conventional design and manufacturing to additive processes. The results are clear: components become lighter, smaller and may even integrate more functions.

Nevertheless, the conversion process is progressing slowly. There are several reasons, starting first and foremost with the demand for maximum safety. With existing design and production processes, all necessary qualifications are available for the required safety of components. For 3D printing, unfortunately, we are still at the beginning and, therefore, invest a lot of time and energy in process qualifications. We have to ensure that the internal structures and the surfaces meet all the requirements for permanent, safe operations. In parallel, we are, of course, continuing to work on optimizing the processes, on new material combinations and design processes, because we are certain that 3D printing will be indispensable for the climate-neutral aircraft of the future.

Volker Thum | BDLI Bundesverband der Deutschen Luft- und Raumfahrtindustrie e.V.

Volker Thum

09:45 - 09:50
Greetings from the Rapid.Tech 3D Live-TV-Studio
09:50 - 10:00
Break & Chat Roulette
10:00 - 14:00
Live-Stream: Forum "Software, Processes & Design" and Forum "Medical, Dental & Orthopaedic Technology"
14:00 - 14:15
Coffee break and Chat Roulette
14:15 - 14:45

Additive manufacturing (AM) allows for the production of previously unseen parts with any degree of complexity for organic shapes or internal features. In aerospace applications, engineers can take full advantage of these new design possibilities to optimize parts under consideration of weight reduction without losing mechanical strength. Before such parts are used in-flight, they typically have to pass a thorough quality inspection. Such an inspection should ideally be non-destructive and compliant with the geometrical complexity of the samples. Here we present a case-study on the non-destructive quality evaluation of additively manufactured reaction wheel brackets for the Eutelsat KONNECT satellite. To have a full 3D inspection of the material health of these brackets, we used industrial computed tomography (CT) imaging. This x-ray based method results in a 3D volumetric dataset of the sample that can virtually be sliced through any chosen plane of section. By this, voids such as porosities, foreign particle inclusions, or lacks of fusion can be visualized. This data can further be used to compare the geometry of the actual part to its nominal CAD data in order to highlight shape deviations and thus provides a comprehensive inside view on quality topics relevant for AM parts.

Dr. Thomas Kleinteich | TPW Prüfzentrum GmbH


14:45 - 15:15

 Additive Manufacturing provides a unique design freedom for the manufacture of complex structural and functional components. Due to the low quantity of products that is typical for the space industry, AM shows promising applications for satellites.
In contrast to traditional manufacturing, for AM the material properties cannot be taken from a material database, since they are generated just during the process. Experience shows that the component quality depends on the raw material, the process parameters, the type of AM system and the individual component supplier. Thus, a robust and reliable process chain is essential to ensure the quality required for flight hardware.
The presentation highlights OHB's approach to implement satellite components using AM. The presented process focuses on the interaction between design and structural analysis using topological optimization. Recently developed components are presented to illustrate the advantages of the technology over conventional solutions. An outlook is given on material validation, process control and part verification for flight hardware.

Dr. Marco Mulser | OHB System AG



15:15 - 15:45

The production of large structures made of expensive metallic materials poses major logistical and economic challenges for the aerospace and other industries. Classical powder bed based additive manufacturing processes are hardly suitable for the economic production of large structures due to limited build space and the recycling of large quantities of metal powder.
For this reason, MT Aerospace is pursuing the two processes of Additive Friction Stir Welding and Directed Energy Deposition with the aim of producing both hybrid and fully additive components which meet the highest requirements in terms of process reliability and material properties.
The focus for Directed Energy Deposition is put on titanium alloys, while the Additive Friction Stir Welding process is mainly used for non-weldable aluminum alloys.
In addition to the classic advantages of additive manufacturing, such as shorter leadtimes and more degrees of freedom in product design, both processes offer further unique advantages that make both technologies very interesting for highly stressed large structures.
Directed Energy Deposition is highly scalable, regardless of the type of material feed, since the process nozzle itself can be implemented on different mechanical systems such as robots or gantry systems.
Due to the non-melting joining process, Additive Friction Stir Welding is ideally suited to weld alloys which classically are non-weldable or hybrid applications with excellent material properties.
Both processes as well as applications are presented.

Markus Axtner | MT Aerospace AG



15:45 - 16:00

In the economy, the dynamic competitive environment is giving rise to an increasing urge for shorter product development times, high functional integration and individualized products. Here, additive manufacturing processes (AM) are gaining increasing industrial significance, as they are a key technology for future production due to their flexibility, the use of innovative materials and the sustainable production on a digital basis. In view of these challenges, individualized and complex products and new development processes are addressed as key topics.
As an approach to increase productivity, the combination with established manufacturing processes is used by defining suitable functional carriers of a component, i.e. single elements of a component, whose production obtains an added value by using additive manufacturing processes. Conventional manufacturing processes, on the other hand, are used where they remain more economical or where the scope of application cannot be covered by the conditions of industrial production by AM so far.
The presentation will present an integrative view of the entire hybrid AM process chain with post-processing and further processing by established productive manufacturing processes.
Furthermore, an examination of the energy and resource efficiency as well as the current standardization activities in the wider environment of such a "smart production", which includes the hybrid process chain, is presented. The focus here is on the manufacturing environment with the fundamentals across the entire value network.

Martin Schäfer | Siemens AG



16:00 - 16:15

Over the entire lifetime of an aircraft, sustainability and therefore energy and resource efficiency play a decisive role. This guiding principle must already be taken into account during the production of aircraft components. More than 60 percent of the semi-finished product is machined during conventional production and ensures increased raw material and energy consumption during manufacture.
This is where the concept of hybrid production using laser metal deposition with wire (additive) and machining (conventional) comes together. An additive build-up is carried out locally and flexibly on a semi-finished product as required. The dimensions of the semi-finished product can be made smaller. This leads to a reduction in the amount of material used, shorter machining times, significantly less tool abrasion and lower energy consumption already during production.
In the presentation, this concept will be presented using the example of an aircraft turbine housing, which was developed in the AGENT-3D project IMProVe, funded by the German Federal Ministry of Education and Research (BMBF) and in cooperation between MTU Aero Engines AG and the Fraunhofer Institute for Material and Beam Technology IWS.

Stefan Polenz | Fraunhofer-Institut für Werkstoff- und Strahltechnik IWS

Stefan Polenz studied Material Science at the Technische Universitaet Dresden. He is working as a scientist in the group of Direct Energy Deposition and Hybrid Manufacturing at the Additive Manufacturing Center Dresden (AMCD) at Fraunhofer Institute for Material and Beam Technology IWS. He is working on different scientific research projects. His current projects focus on hybrid manufacturing approaches, especially Additive Manufacturing (Laser Metal Deposition) and wavelength-dependent laser material interaction particularly regard to metallic compounds and ceramic matrix composites.

16:15 - 16:30
Coffee break & Chat Roulette
16:30 - 17:00

The Presentation highlights opportunities and challenges of incorporating AM technology on the Boeing 777X Folding Wingtip System Secondary Lock Actuator.

The Case Study shows how Liebherr addressed challenges like thermal stresses in production, pressure drops in operation, surface treatment and wear surfaces of titanium cylinders.
Furthermore, an outlook will be provided regarding the challenges of the technology and the implementation to serial production of highly integrated components.

Alexander Altmann | Liebherr-Aerospace Lindenberg GmbH
17:00 - 17:05
Farewell to the Rapid.Tech 3D Live-TV-Studio