CAD and additive manufacturing in the aerospace field

Additive manufacturing with CAD software is a three-dimensional production method that enables products to be created by successively adding layers of materials from digital models. It helps to design complex, high-quality parts with a high degree of precision, while reducing material waste compared with traditional manufacturing methods. More and more widely used in France's aerospace industry, among others, additive manufacturing enables the production of light, strong parts, which contributes to reducing the weight of aircraft, improving their efficiency and reducing component maintenance costs.

Additive manufacturing principles

Basics

• Additivity : Additive manufacturing builds objects by successively adding layers of material, unlike subtractive methods, which remove material to obtain the desired shape.

• 3D modelling : Objects are created from three-dimensional digital models, which are then cut into thin layers to guide the process of material addition layer by layer.

• Fusion or conglomeration : The material is fused or conglomerated, whether by laser fusion, sintering, molten wire deposition or other methods, to solidify the successive layers and create the final object.

• Control and precision: Precise control systems are used to deposit or fuse the material with micrometric precision, guaranteeing the quality and dimensional conformity of the object being manufactured.

• Temporary supports : In some processes, temporary supports are used to hold overhanging parts of the part during manufacture, before being removed once the object is finished.

• Post-treatment : After manufacture, post-treatment operations such as polishing, sandblasting, painting or heat treatment may be required to improve the finish, mechanical properties or appearance of the part.

• Parameters optimisation : Process parameters such as laser scanning speed, temperature and powder density are carefully optimised for each specific material and application in order to obtain the best properties and performance from the final part.

Additive manufacturing: a revolution in aeronautical production

To address the challenges of manufacturing costs, safety, time, working conditions and environmental issues, industry must resort to efficient techniques and systems. Companies in the aerospace and aeronautics sectors have obligations in terms of the safety standards of their products. Faster production processes and better management of parts development are driving the industry forward. Here are the benefits of additive manufacturing techniques for aerospace components and products:

• Construction of parts with complex geometries: manufacturing by 3D printing without additional assembly (helicopter parts, turbine engines, etc.)
• Optimised production with a wide variety of materials.
• Creation of light and resistant components: to reduce fuel costs, weight is on average reduced by 25% and the structure is more reliable and resistant since there are few or no external fixings (screws, bolts, etc.).
• Rapid design & production: the design process is smoother and production requires less materials' storage thanks to the manufacture of made-to-measure parts and components.
• Reduced costs for your business: unlike subtractive manufacturing techniques, additive manufacturing generates minimal waste and does not require moulds, for example

Additive manufacturing in the aerospace industry is relevant to a wide range of professions: production manager, design office manager, design technician, design engineer, 3D printing technician, quality control technician, maintenance specialist, digital and IT training manager, etc. More and more engineering school students are opting for a course of study in the computerised design and manufacture of aeronautical products, and receive in-company training that often enables them to learn about the adoption of 3D printing techniques and their uses in this industry.

 

Challenges and innovations of aeronautical 3D printing

• Respect of strict safety requirements. Additive manufacturing ensures that parts comply with industry-regulated standards.
   
• As the production process is accelerated, software users need to be effectively trained in the design and manufacturing tools and machines to ensure quality machining and a rapid & reliable increase in skills. Find out more about the importance of CAD / CAM Training.
   
• Le processus de développement des pièces et produits doit rester rentable. 
   

For these reasons, certifications have been established to guarantee the quality of aircraft components, such as CFM International's LEAP engine. For years, studies have been constantly carried out to develop the tools needed for the rapid manufacture of aircraft components. AI now uses machine learning programmes to generate a printout that takes constraints into account, while leaving plenty of room for creativity in terms of design. Additive manufacturing facilitated by the adoption of high-performance CAD software (such as NX CAD for additive manufacturing) therefore represents a springboard for the aerospace industry.