Page 9 - AAA SEPTEMBER - OCTOBER 2016 Online Magazine

FEATURE MRO

In August, the Guinness World Records, the point that it had begun adding concrete is considering, rather it is a platform to
granted the title of largest solid 3D printed value to the business,” says Remacha. “As enable low-risk and fast-track development
item to a 3D printed trim-and-drill tool, that costs continue to drop and quality rises, of different technologies in real flying
was developed by researchers at the U.S. 3D prints can significantly help companies conditions,” explained Detlev Konigorski of
Department of Energy’s Oak Ridge National introducing innovative solutions without Airbus’ Emerging Technologies & Concepts
Laboratory (ORNL) for evaluation by Boeing. huge investments or inventory expenses,” activity in Germany, who oversees the
“The existing, more expensive metallic he adds. GE’s most sophisticated turbine THOR project. “The first version was
tooling option we currently use comes from a blade design concepts are now on test in two to test whether the slogan ‘Print me an
supplier and typically takes three months to weeks, not the nine months it once required, airplane’ can be converted into reality.” The
manufacture using conventional techniques,” thanks to rapid prototyping and 3D printing. short lead time of 3D-printing, is a major
said Leo Christodoulou, Boeing’s director MRO provider MTU is already well prepared advantage for THOR and significantly
of structures and materials. “Additively for MRO activities with additive layer reduced development time for producing
manufactured tools, such as the 777X wing manufactured parts. “At MTU Maintenance, the technology demonstrator compared to
trim tool, will save energy, time, labor, and we have an industrial engineering department traditional manufacturing methods. It took
production cost and are part of our overall that concentrates solely on improving our approximately seven weeks to print the
strategy to apply 3D printing technology repairs, processes and technologies. Among THOR aircraft’s 60 structural segments,
in key production areas.” The 17.5ft long x other things, they are currently exploring approximately one week for assembly
5.5ft wide x 1.5ft tall, 3D printed structure is additive manufacturing technology, for and three days to fine tune the electrical
comparable in length to a large sport utility instance in blade tip restoration,” says Frank systems before it was flight-ready.
vehicle and weighs approximately 1,650 Bodenhage, President and CEO of MTU
lb. The lower cost trim tool was printed at Maintenance Zhuhai. “On a broader company
ORNL in only 30 hours using carbon fiber group level, MTU Aero Engines already
and ABS thermoplastic composite materials uses additive manufacturing to produce
and will be tested during the manufacture boroscope bosses for the PW1100G-JM oPPosite PaGe: 3D printed trim
of the Boeing 777X. The tool will be used that powers the A320neo. Another example tool co-developed by ORNL and
to secure the jet’s composite wing skin for is a new seal carrier that was designed for Boeing which achieved a Guinness
drilling and machining before assembly and a demonstrator engine based on Pratt & World Record title for the largest
following completion of verification testing Whitney’s PW1500G,” he adds. solid 3D printed item. The 3D
printed trim-and-drill tool weighs
by ORNL; Boeing plans to use the additively Airbus is presently undertaking work on approximately 1650 lb
manufactured trim-and-drill tool in the its Testing High-tech Objectives in Reality
company’s new production facility in St. (THOR) mini aircraft project; a testbed for aBoVe: Detlev Konigorski, Gunnar
Louis and provide information back to ORNL 3D-printed structural parts and advanced Haase and Andreas Poppe (from
left to right) with individual printed
on the tool’s performance. aerodynamics. “This mini aircraft does not parts of the four-metre-long Airbus
“3D printing technology has developed to represent an actual airliner design Airbus THOR project aircraft
WWW.GBP.COM.SG/AAA SEPTEMBER / OCTOBER 2016 ASIAN AIRLINES & AEROSPACE 9