Aerospace & Defence

One of the key benefits of 3D printing for Aerospace and Defence is its flexibility in design. This technology can be used to combine multiple parts into a single, more efficient component.

For example, a world leader in aerospace manufacturing used 3D printing to combine 855 separate parts into just 12 components for their ATP engine, with one-third of the engine being 3D printed. Similarly, it also used 3D printing to combine more than 300 engine parts into just 7 components, which is the most powerful engine in the world and 10% more fuel-efficient than its predecessor.

In addition to its design flexibility, 3D printing also offers increased productivity and the ability to create tailored solutions for specific needs.

We can help 3D print the parts from airfoil part families, casing part families, accessories and other part families.

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Turbine Blades

A leading aeroengine manufacturing company used 3D printing to manufacture the low-pressure turbine (LPT) blades for one of its most powerful engines used in commercial airplanes.

Traditionally, these blades would be produced using a casting process, but the company turned to additive manufacturing as an alternative method.

The 3D printed LPT blades, made using a metal 3D printer and titanium aluminide powder, are able to withstand high temperatures and pressures as they spin at 2500 rpm on a disk. They are also much lighter than blades made using conventional materials like Ni alloy, weighing 50% less.

One of the key benefits of using 3D printing to manufacture these LPT blades was the ability to produce them in high quantities. The Arcam machine was able to produce six blades simultaneously, significantly increasing production rates compared to traditional methods.

Overall, the use of 3D printing for the production of LPT blades in the engine demonstrates the versatility and efficiency of additive manufacturing. Its ability to create strong and heat-resistant parts, while also reducing weight, makes it an attractive option for a range of applications.

Sump Cover

The sump cover of the military engine is an essential component that helps to protect the engine and keep it running smoothly. In the past, these parts were traditionally manufactured using a casting process, but one company decided to explore the use of additive manufacturing as an alternative method.

The company identified the sump cover as a replacement part that would need to be replaced during maintenance, but discovered that it was no longer in production at the original equipment manufacturer (OEM) or any vendors. This presented a challenge, as the company needed a way to obtain these parts in a timely and cost-effective manner.

To overcome this challenge, the company turned to 3D printing using a metal 3D printer and cobalt chrome powder. The additive manufacturing process allowed them to produce the sump covers on demand, without the need to rely on traditional manufacturing methods or wait for parts to be sourced from external vendors.

Overall, the use of 3D printing for the production of sump covers in the military engine demonstrates the versatility and flexibility of additive manufacturing. Its ability to produce parts on demand, even for components that are no longer in production, makes it an attractive option for companies looking to streamline their supply chains and reduce downtime during maintenance.

Injector Head

The injector head of the rocket engine is a critical component that helps to feed the fuel mixture into the combustion chamber. Its traditional design consists of 248 components, produced and assembled through various manufacturing steps like casting, brazing, welding, and drilling. These steps can lead to weak points in the injector head, posing a risk under extreme load conditions.

To address this issue, a company decided to use 3D printing, to produce the injector head. Using a metal 3D printer and Inconel 718 powder, the company was able to streamline the production process and eliminate many of the weak points present in the traditional design.

In the conventional production process, over 8000 cross holes needed to be drilled into copper sleeves that were then precisely screwed onto 122 injector elements in order to mix hydrogen with oxygen as it flowed through them.

With 3D printing, the company was able to simplify this process, creating a more efficient and reliable injector head that could withstand extreme load conditions.

Overall, the use of 3D printing for the production of the injector head in the rocket engine demonstrates the benefits of additive manufacturing for complex components. Its ability to streamline the production process and eliminate weak points, while also providing precision and reliability, makes it an attractive option for a range of applications.