Aerospace And Defense

Aerospace And Defense

Introduction

This sector has been leading the way in adopting new technologies, driven by a need to control costs, quality and traceability within the product lifecycle. The A and D industries face the need for compliance with industry standards and require the ability to document and control the data related to their products and processes for the duration of extended product lifecycles. Therefore OEMs and their suppliers and collaborators, and MRO companies can benefit from driving their product development through to their aftersales and maintenance with a PLM system. PLM solutions are becoming the standard platform for companies to enhance the effectiveness of their people and processes and facilitate global collaborations within the Aerospace and Defence sector.

With PLM from world-leader Dassault Systemes, comes the ability to create products within a 3D lifelike environment with the digital mock-up, (design, prototyping, analysis, simulation, manufacturing and assembly),  providing unprecedented visualization, helping to eliminate errors, reduce overall production costs and reach important deadlines.

New trends in producing parts and components for aerospace and defence

 Latest technologies such as 3D scanning and direct digital manufacturing, (DDM), can be used to change the way products are designed and manufactured, helping to revolutionize the industry.  Companies have the ability to ensure the highest quality of parts, components and assembled products that can be created with innovative materials, such as composites, to industry standards. Market leader in supplying rapid prototyping and DDM systems, Stratasys Inc., has been working closely with the Aerospace and Defence industries for many years to develop significant innovations in the production of parts, components, and jigs and fixtures, with new materials and production methods. FDM technology gives you the most flexibility with a variety of thermoplastics designed for aerospace applications – like Ultem. Read case studies to learn how FDM technology is streamlining design and manufacturing in the aerospace industry.

Latest technology for rapid manufacturing of metal parts with investment casting is opening new opportunities for low volume or custom production and manufacturing on demand, which for aircraft and defence parts can save critical downtime. Read more to discover how leading Aerospace and Defence companies and their supply chains are using technology to create competitive advantage and how D2M Solutions can assist your company.

Solutions for: Aerospace & Defence OEMs, supply chain partners, (parts and components), MRO suppliers, UAV design & manufacture.

Aerospace and defence product development, product lifecycle management PLM, supply chain management, program and project management, reverse engineering of parts, compliance with standards, MRO quality control, CMM inspection.

For more information on how your company can benefit, please contact the D2M experts here

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Custom Solutions

Aerospace And Defense

Custom Solutions

ON DEMAND SPARE PARTS – CIVIL AVIATION

 THE NEEDS OF THE INDUSTRY

It is no secret that the airline industry (in particular the airlines) face a big problem sourcing and stocking spare parts for the interiors of the aircraft. These are often parts that can be relatively easily reverse engineered and replaced using 3D printed parts in ULTEM 9085 and 1010 aerospace certified materials.

This solves one of the greatest issues faced by airlines, which is ensuring that aircraft spend a minimum time on the ground and the maximum time flying.

THE SOLUTION

  1. 3D Scanner for the quick acquisition of the 3D geometry of parts.

By utilizing the latest in handheld 3D scanning technology, ground crews can quickly and easily capture the complete geometry of interior components. This can later be sent to engineering departments for modeling in CAD software, alterations or developments of the original design.

  1. 3D printing of the components in aerospace certified material.

The 3d printing of interior components has started to make its way into the OEM productions cycle, with examples such as the Airbus A350 which now has more than 1,000 components 3D printed into the production aircraft.

The 3D printing process using Stratasys FDM systems has been designed for production accuracy, so even larger production runs of 100s or 1000s of components can be produced.

If a component cannot be 3D printed, design teams can easily produce the tooling necessary for different production methods, such as vacuum forming tools and sheet metal forming tools.

  1. Part finishing

The printed parts can be painted, electroplated or finished using hydrographic film transfer for a variety of aesthetically pleasing and certified results. The finishing process does not vary significantly for 3d printed parts versus parts produced using traditional methods, so the process is easily adopted by engineering and fabrication crews.

THE BENEFITS OF THE SOLUTION

  • Simplification of spare parts logistics chain, as parts can now be produced locally.
  • Huge cost reductions on parts which have to be ordered as an assembly – end users can now only produce the relevant component and re-use undamaged parts of the assembly.
  • If parts cannot be printed, there is a high possibility that tooling would be able to be produced to manufacture the component (such as vacuum forming tools) which vastly increased the number of materials that the final component can be manufactured from.
  • Aircraft down-time greatly reduced.
  • Digital library of parts can be created, which can be used at whatever time to produce more spare parts.
  • Using 3D scanning you can severely reduce the turnaround time on modeling spare parts.
  • Costs of maintaining the interiors of the fleet are greatly reduced.
  • ULTEM 9085 & 1010 can go directly on aircraft without the need for any treatment.

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DEFENSE SPARE PARTS INDUSTRY

 THE NEEDS OF THE INDUSTRY

The defense industry has a huge need for the quick reproduction or spare parts, both for vehicles and for land based assets. These parts can fall into one of the following categories:

  • long lead time parts
  • obsolete components
  • complex high value (non critical) components
  • assemblies
  • volume production

D2M can now propose a solution to address all the above categories. The solution consist of a ready center (all equipment and software) necessary to digitize and reproduce (or design from scratch) almost any component listed in the above categories (in a variety of materials and sizes).

By utilizing the latest in 3D scanning (laser scanning and CT scanning), 3D printing, CAD/CAM/CAE and PLM (product lifecycle management), CNC machining (parallel kinematics) and Rapid Sand and Investment Casting Solution which all come together to allow the end user to receive components scan them and then select the best way to reproduce.

Obsolete components that can often be very hard to find and can lead to the decommissions of complete equipment if they cannot be found can now be reproduced and the intellectual property save in a digital library of parts for future reproduction. This can lead to the extension of the useful life of a large amount of assets.

THE SOLUTION

  1. 3D Scanner for the quick acquisition of the 3D geometry of parts.

By utilizing the latest in handheld 3D scanning technology, ground crews can quickly and easily capture the complete geometry of interior components. This can later be sent to engineering departments for modeling in CAD software, alterations or developments of the original design.

  1. 3D printing of the components for low volume manufacturing of plastic parts or test part.

3D printing in the defense industry can be used for either printing low volume end-use plastic components, or the can be used to produce test parts for validation, before an investment is made in permanent tooling or metal components. Production systems can also be used to produce a variety of manufacturing tools (such as sheet metal tooling) to allow the end user to produce a further amount of parts by using the 3D printed tooling, adding to the capabilities of local manufacturing.

  1. 3D printing of complex sand cores

3D printed sand cores can drastically reduce the time needed to produce a fully functional sand mold for the casting of metals. By using this method of additive manufacturing, extremely complex designs can be produced effortlessly. The cores can be delivered to the foundries for casting on a just-in-time basis, reducing the need for keeping large numbers of stock components.

  1. Rapid Investment Casting

Investment casting can be used to produce castings which require better accuracy than sand casting. Complete lines can be set up which are capable of producing low volume runs of parts, allowing end users stock only the number of parts they require.

  1. CT Scanning for reverse engineering and quality control

CT Scanners have the added benefit of being able to scan “hidden” features of components, since the x-rays penetrate the entire part. Quality control on the castings can also be performed to make sure that no air bubbles or cracks are present in the final part.

  1. CAD/CAM/CAE and PLM Solution

By using the latest 3D design and simulation tools, designers can reduce the time needed to redesign components and deliver larger volumes of work in a more effective way. At the same time, all the IP that is created during the designing or digitization of parts is saved in the PLM layer in an organized fashion for reuse whenever required.

The PLM platform shall also be used to manage projects and the people involved in these projects through the extensive capabilities of the platform. By connecting the design capabilities to all other aspects of the organization, errors and problems can be identified sooner and changed earlier leading to plenty of optimizations and cost reductions.

  1. Parallel Kinematics CNC machining

Parallel Kinematics machining is a combination of capabilities of high end robotics and multi axis machining, which results in an extremely fast system that can be used to do all the finishing on the casted parts.

THE BENEFITS OF THE SOLUTION

  • Simplification of spare parts logistics chain, as parts can now be produced locally.
  • Huge cost reductions sourcing obsolete components.
  • Reduction in stock numbers, as end users have the capability to produce just in time parts, or keep only a minimum amount of spare parts,
  • Long lead times can be reduced from years to a couple of days in some cases.
  • The lifecycle of equipment with obsolete components can be significantly extended since parts can be produced locally.

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For more information on how your company can benefit, please contact the D2M experts here

Leaflets

Aerospace And Defense

Leaflets

Significantly Increase Competitive Advantage

How do you deliver programs
on-time, on-budget, and on-target?

Engineered to Fly

Digital continuity enables improvements for up to 30% Error Reduction 40% Productivity Boost 40% Process Changes Requested

3D Scanning and Reverse Engineering in Aerospace

Metrology in aerospace

Engineering Service in Aerospace Industry

Design, Retrofiting,
and Simulation in aerospace industry

Videos

Aerospace And Defense

Videos

Harrier Jet, replacement of parts

United Launch Alliance Talks About Innovation

Aerospace Parts

Co-Design to Target

White Papers

Aerospace And Defense

White Papers

Additive Manufacturing for Aerospace

Constant Improvement: Jeff DeGrange on the state of additive manufacturing for aerospace.

Additive Manufacturing Trends

Additive Manufacturing Trends in Aerospace leading the way!

Take Control

Protect Your Intellectual Property

Managing Contracts in Aerospace & Defense

Managing Contracts More Reliably with PLM

Case Studies

Aerospace And Defense

Case Studies

The New Industrial Revolution

The New Industrial Revolution: D2M Solutions Discusses the Concept & Implications of 3D Printing in Gulf Industry Magazine

Direct Digital Manufacturing Takes

FDM Direct Digital Manufacturing Saves $800,000 and Three Years Development Time Over Four-Year Period

FDM -DDM Saves $800,000

“FDM has saved the government over $3.8 million to  date with an expected 10-to-15-year savings of over  $15 million.”