Forum Aviation

WEDNESDAY, 6 May 2020

Location: CongressCenter, ground floor, Room Carl Zeiss left

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08:45 - 09:45
09:45 - 09:50
Welcome Carl-Zeiss Saal
09:50 - 10:30


Keynote 6 May 2020
Session 1
10:30 - 11:00

Among the production processes of thermosetting matrix composites, the hand lay-up is
the simplest and oldest open moulding method for composites manufacturing. If it is
required high dimensional stability during the thermal cycle, the moulds are generally
realized in steal and aluminium alloy or in carbon resin. Compared to traditional moulds the
use of a 3D printer with polymers, instead of metals, allows the manufacturer to save time
and costs, with the advantage of producing personalized parts.
With a leading aerospace company, it is reported a case study of a lamination obtained on a
high precision 3D printed mould with CARBON PEEK, carbon fiber filled PEEK, thanks to
Roboze FFF 3D printing technology.



11:00 - 11:30


11:30 - 12:00

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


12:00 - 12:30

Process-Structure-Property-Correlation of additively manufactured Ti6Al4V - Influence factors and experimental validation

Prof. Dr. Martina Zimmermann | Fraunhofer Institut für Werkstoff- und Strahltechnik


12:30 - 14:30
Lunch break and visit to the trade show
Session 2
14:30 - 15:00

The probation period is over. AM applications for aviation and aerospace industries are real now.

Lars Langhans | FIT AG


15:00 - 15:30

Aviation is seen as one of the largest markets for additive manufacturing and serial production in civil aviation would consequently be the holy grail. Powder Bed Fusion (PBF) components have recently made it on the first aircraft programs, replacing brackets, subassemblies or subsystems. However, the technology has not yet left the "through of disillusionment". A lot less fancy, but luring with larger cost saving potential from less parts, Directed Energy Deposition (DED) is the new Metal AM Technology that is approaching serial production. It addresses very cost-intensive large structural titanium components with long lead-times.
Qualifying PBF processes, as well as planning the supply chain and managing the production, while protecting the business case against hidden cost and a very long process chain were the challenges of the past. Those lessons learned from PBF can be transferred to enable DED.

Dr. Jan Roman Hönnige | Premium AEROTEC GmbH
15:30 - 16:00

Additive Manufacturing for Space – New opportunities for satellite structures

Dr. Marco Mulser | OHB System AG
16:00 - 16:30