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Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
Airbus Additive Manufacturing 2014
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Airbus Additive Manufacturing 2014

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  • 1. © AIRBUS S.A.S. All rights reserved. Confidential and proprietary document. Additive Layer Manufacturing: A new Perspective in Structural Design Presented by Matthias Radny, Structural Optimisation Dirk Elbracht, Fuselage Structure Design
  • 2. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. The Future Aircraft Month 200XUse Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference Page 2
  • 3. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. Airbus Concept Plane 2012Technical Event ESBSR internal 3.9.2012 Page 3
  • 4. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. Month 200XUse Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference 3D Printing, Additive Manufacturing, Prototyping Page 4 ALM allows manufacturing of very complex shapes This Family of Technologies is gaining momentum world-wide. There is a significant opportunity to change the Development Process to an optimum. Source: iLAS / TUHH http://www.lzn-hamburg.de/technologien/weitere-qualifikationen/konstruktion/bionische-gestaltung.html
  • 5. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. A main driver for 3D printing Month 200XUse Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference Page 5 • Conceptual Topology Optimisation is an enabler for a new way of designing efficient Airframe structures. Source: http://www.altairhyperworks.de/Product,60,Inspire.aspx
  • 6. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. A main driver for 3D printing Month 200XUse Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference Page 6 Topology Optimization Geometry Extraction ICAD Solid Geometry Extraction Size and Shape Optimization Geometry Extraction Topology OptimizationStiffness Material Layout Size and Shape Optimization Buckling and Stress Topology OptimizationDesign Space and Load Mass Savings of 44% (500kg) 13 Ribs developed in 7 weeks Potential Drivers are Weight Saving (step change for topology), Cost Saving and increased Flexibility.
  • 7. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. Challenges for Processes, Tools and Way of Working Month 200XUse Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference Page 7 Today people think in a subtractive way. Processes and Tools are built in the same way. A  step  change  is  needed  to  think  and  work  in  an    „additive  way“!
  • 8. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. Scheme of Development Process Evolution Month 200XUse Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference Page 8 Optimization of the Design Process Geometry definition Virtual verification Physical verification Integrated Design and AnalysisVerification (CAE) Physical Test Optimization (CAE) Design (CAD) Verification (CAE) Physical Test Design (CAD) Structural optimization (CAE) Traditional Design Process Optimization to improve existing Design Optimization driven Design Process State of the Art Partially applied today Future way of working / Design Vision Stress and Design perimeters will converge. a new Skill will be needed and is under definition. Design (CAD) Verification (CAE) Physical Test
  • 9. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. Example: Cargo Door Actuator Beam Actuator Beam today is a typical milling part Topology Result taking into account all applied Loads
  • 10. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. Actuator beam in different Manufacturing Processes Actuator Beam as casting part Actuator Beam as milling part Actuator Beam as Additive Layer Manufacturing part Source: Michael Mues; DESIGN INTERPRETATION OF TOPOLOGY OPTIMIZATION RESULTS AND DEVELOPMENT OF A METHOD FOR 3D ALM DESIGN WITH STIFFENER STRUCTURE, Diploma Thesis, FH Aachen 2013 There is significant Weight Saving potential into new Design Concepts!
  • 11. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. Al Alloy eg. AlMgSc, loaded and lightly loaded parts Ti + other Hard Alloy eg. Fittings Plastic eg. Brackets, low loaded items Month 200XUse Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference Additive Layer Manufacturing at Airbus R&T mid-long term Strategy - Strategy Schematic Page 11 MATURITY Bionic Design / Topology Optimisation Capability Incl: Production tooling Customer Service parts PROCESS  DEV’T     + QUALIFICATION TIME
  • 12. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. Potential Roadmap: Mid-Term Month 200XUse Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference Page 12 Structural and System Installation Parts CAO (Computer Aided Optimized) Primary Structural Components Today Mid Term
  • 13. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. Potential Roadmap to Future Aircraft Month 200XUse Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference Page 13 Tomorrow Integrated Multi Functional Component (Structure and System) through Multi-Material Additive Manufacturing
  • 14. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. Thank you Month 200XUse Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference Page 14
  • 15. © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. Month 200XUse Tab 'Insert - Header & Footer' for Presentation Title - Siglum - Reference © AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS Operations GmbH. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS Operations GmbH. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS Operations GmbH will be pleased to explain the basis thereof. AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks. Page 15

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