UP F RONT
NEW DIMENSION
Big names in aviation are investigating the use
of additive manufacturing (AM) to 3D print
parts on demand, which can reduce flight
delays and simplify logistics. 3D printing can
produce parts that, while as strong and durable
as traditional components, weigh up to 55%
less. Let’s explore the latest developments…
aircraftinteriorsinternational.com
018 MARCH 2020
1
BA’S SMALL STEPS
TO BIG BENEFITS
British Airways is exploring the possibility of using
3D printers located at airports around the world to
manufacture replacement aircraft cabin parts on demand.
The airline predicts that many non-essential cabin parts will soon be 3D
printed, including components for tray tables,
IFE systems and toilets. Such components
may not affect the safe operation of a flight,
but if broken they can reduce the number of
seats or toilets available for customers and
cause delays in turnaround times as
engineers wait for the parts to be delivered
to wherever the aircraft is in the world.
3
QATAR AIRWAYS INSTALLS
LARGEST 3D-PRINTED PART
5
EMIRATES PURSUES 3D PRINTING
Emirates is using Selective Laser Sintering (SLS) 3D-printing to produce
IFE video monitor shrouds from powdered aerospace-grade Duraform
ProX FR1200 thermoplastic. According to Emirates and its partners,
monitor shrouds that are 3D printed using the SLS technique can weigh
between 9 and 13% less than components manufactured traditionally
or by FDM. The shrouds have already undergone a range of structural,
durability, flammability and chemical tests, and upon receiving EASA
certification the shrouds will be
installed on select aircraft in the
Emirates fleet and will be tracked
for data collection as part of their
evaluation in terms of on board
durability and wear and tear. The
airline has also gained EASA
certification for the 3D printing and
installation of cabin air vent grills
for onboard trials.
2
EASA APPROVES ETIHAD ENGINEERING
In 2017, Etihad Engineering received EASA approval to 3D print with
filament technology, becoming the first airline MRO to certify, print
and fly 3D-printed cabin parts. The company now has EASA approval
covering powder bed fusion 3D-printing technology and has opened
the first AM facility in the Middle East region, with approval from EASA.
Etihad Engineering collaborated with 3D printing technology providers,
EOS and BigRep, to create the facility in Abu Dhabi, which will enable
the design, production and certification of 3D-printed cabin parts.
The laboratory features two industrial 3D printers: the P 396
powder-bed fusion technology system from EOS, which enables faster
production of serial components, spare
parts, functional prototypes and models;
and BigRep ONE, one of the largest serialbuilt
industrial thermoplastic extrusion 3D
printers, which can manufacture large
parts, jigs and fixtures, and moulds.
4
BOEING HORIZONX INVESTS IN
HIGH-SPEED METAL PRINTING
Boeing’s Horizon X innovation fund has invested in
Digital Alloys, a Massachusetts-based company that
develops high-speed, multi-metal AM systems. Boeing
is no newcomer to 3D printing and its time- and costsaving
benefits, with more than 60,000 3D-printed parts
flying on its various space, commercial and defence
products. The attraction to Digital Alloys is its Joule
Printing technology, which can rapidly combine multiple
metals into each part, a process which is claimed to
enhance thermal, electrical, magnetic and mechanical
properties. The process allows metals such as titanium
and high-temperature alloys to be 3D-printed for parts
that could be used on Boeing products. The process is
claimed to offer lower cost and complexity than powderbased
3D-printing systems, and higher resolution than
other wire-based 3D-printing techniques.
Visit aircraftinteriorsinternational.com for regular cabin materials and production news
Boeing is
exploring using
3D printing for
low-volume parts,
from armrests to
interior panels
Diehl Aviation has delivered its
largest, fully 3D-printed part for
a passenger aircraft to date.
The part in question is a curtain
comfort header – a complex
enclosure for the class divider
curtain rail – for installation on a
Qatar Airways A350. The module
was manufactured using fused
deposition modelling (FDM) and
measures 1,140 x 720 x 240mm.
The project took 12 months
from initial concept to EASA
certification and delivery, and
Diehl Aviation has stated that it
will now only use FDM to produce
curtain comfort headers for the
A350. These modules are usually
formed from numerous layers of
laminated fibreglass, each of
which requires its own individual,
complex aluminium tool. However,
when produced using FDM, the
complete module is comprised
of up to 12 component parts – all
of which are produced by a 3D
printer and simply glued together
when complete.
/aircraftinteriorsinternational.com
/aircraftinteriorsinternational.com