Peter Zimm - MRO WORKSHOP - SPOTLIGHT: Additive manufacturing (3D printing) is expected to have a profound impact on global supply chains, including in the aviation industry. What does 3D printing mean for the future of manufacturers and MROs?

Additive Manufacturing for MRO
Rio de Janiero, Brazil
30 March
2017
Peter C. Zimm
Principal  ICF
peter.zimm@icf.com

ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Additive manufacturing (AM) “builds up” parts with material deposition,
rather than removing material through machining
ADDITIVE MANUFACTURING FOR MRO
TRADITIONAL MACHINING – “SUBTRACTIVE MANUFACTURING” ADDITIVE MANUFACTURING – “3D PRINTING”
Source: Simtech Simulations, MakerBot
3/30/2017 2
Large percentage of material wasted Complex structures impossible with subtractive
manufacturing techniques

Additive machines are distinguished by the combination of material
feedstock and heat source
3/30/2017 3
Source: ICF
Power / Heat Source
Laser Electron Beam Plasma Arc
MaterialFeedstockType
WireFeed
Blown
Powder
Powder
Bed
ADDITIVE MANUFACTURING TECHNOLOGIES

Two main types of processes are used for aerospace additive
manufacturing
3/30/2017 4
Source: Loughborough University, InssTek, Carbon3D, GE
Powder Bed Processes Direct Metal Deposition (DMD)
Material deposited before processing Material deposited during processing
Materials include Aluminium, Titanium alloys, Cobalt Chrome,
Stainless Steel, Silver, Gold as well as various plastics
Main metals are Cobalt Chrome and Titanium
Great surface finish and precision
Primarily for low-volume parts
Relatively high material deposition rates – better for serial
production
May require more post-processing
Size limited by processing chamber Size only limited by range of motion of deposition head

Additive manufacturing offers many benefits to manufacturers
Drivers of
AM
Adoption
Lower Buy-To-
Fly Ratio
Lightweight
Designs
Part
Consolidation
Shorter Lead
Times
Small Lot
Sizes
Rapid /
Frequent
Prototyping
Enables More
Complex Part
Designs
3/30/2017 5
Source: ICF

Assemblies and
complex parts
are prime
candidates for
AM processes
Whole Parts (Direct)
AM is well suited
to low volume,
high lead time
items such as
tooling, molds,
and fixtures
Whole Parts (Indirect)
Protrusions,
bosses, and
flanges could be
added to
simplified forged
rings
Add Features
Additive manufacturing can be used to make whole parts (whether direct or
indirect) as well as add features to existing parts
3/30/2017 6
USES OF ADDITIVE MANUFACTURING
Source: GE, EOS

CFM LEAP
Fuel
Nozzles
787
Production
Ducts
Housing &
Casing
Features
Liebherr
Prototype
Valve
Manifold
Additively
Repaired
Blade
P&W GTF
Compressor
Stators
Turbomecha
Fuel Injection
Nozzles
While early additive production achievements had been on small complex
parts (e.g. aero engine components) …
3/30/2017 7
QCOMPLETE PARTS QASSEMBLIES QFEATURES QREPAIRS
Source: ICF SH&E analysis, Boeing, Airbus, GE Aviation, DM3D, EU Project Merlin (Rolls-Royce)

… current technologies also allow the additive manufacture of large parts
3/30/2017 8
Trent XWB Front
Bearing Housing
 1.5m in diameter
 Largest ever civil aero
engine component
 Constructed from 48
additively manufactured
vane components
Genx, GE9X LPT
Blades
 Constructed by Avio Aero
(GE subsidiary)
 Made from TiAl using EBM
 Production rate nearly
matches that of casting
Norsk Titanium
Preform
 Wire and plasma arc DMD
technology used
 No necessary post
processing i.e. heat
treatment
 In the process of becoming
aerospace qualified

Additive manufacturing is making deeper inroads in engine production
3/30/2017 9
 Siemens have recently completed full load engine tests
for their additively manufactured turbine blades
 The blades were run at 13,000 rpm and reached
temperatures over 1,250°C
 The blades incorporated redesigned improved cooling
features that help to increase the efficiency of the blade
Source: GE Reports, Siemens
 GE are planning to build the world’s first turboprop
engine that utilizes additively manufactured components
for the Cessna Denali
 Designers consolidated 845 parts into 11 3D printed
pieces, which will reduce production times
 Other claims include a fuel burn reduction of 20% and a
10% increase in power as well as a reduction in the
weight of the engine

The advent and adoption of additive manufacturing for aerospace
production has been well publicized …
3/30/2017 10
Source: Norsk Titanium, GE, Airbus, ICF
Thousands of polymer additive parts have been flying for years – it is metal additive that is emerging

… but a number of additive manufacturing benefits are also applicable to
parts found in mature and sunset aircraft
3/30/2017 11
APPLICABILITY OF ADDITIVE MANUFACTURING BY LIFE CYCLE STAGE
Source: ICF
AM Benefit Design Growth Mature Sunset
Lightweight Designs X
Part Consolidation X
Rapid Prototyping X ?
Complex Designs X
Reduced Material Cost X ?
Reduced Labor Cost X ?
Reduced Tooling Cost X X X
Short Leadtimes X X X X
Small Lot Sizes X X X

The EU’s RepAIR Program aims to integrate additive manufacturing into
aircraft MRO
3/30/2017 12
Source: EU Seventh Framework Program / University of Paderborn: “RepAIR – Future Repair and Maintenance for Aerospace Industry”
University of
Paderborn (UPB)

The study found additive manufacturing could provide numerous benefits
to MRO
 Reduce repair and overhaul costs of complex spare parts by 30% and the turnaround time by 20%
 Increase the automation level for spare parts production processes by 20%
 Reduce scrap and toxic chemicals in the repair process by 80% and part weight by min 20%
 Increase the technology readiness level (TRL) of innovative repair processes to level 4 focusing on the AM
technology
 Develop processes to decrease certification effort for additive manufactured aeronautics and air transport spare
parts in terms of cost and time based on an integrated quality control and process data monitoring
 Reduction of inspection time by 30% by integrating continuous health management and usage-based prognostics
 Strengthen the business model of European MRO service provider in the world by integrating a complete
production and supply chain for complex spare parts
RepAIR 2020 Objectives
 Shorter lead times
 Optimized fabrication in terms of material costs
 Lightweight design of AM parts reduces part and lifecycle costs of airplanes
RepAIR Additive for MRO Findings
3/30/2017 13
Source: EU Seventh Framework Program / University of Paderborn: “RepAIR – Future Repair and Maintenance for Aerospace Industry”
 Lower overall part cost
 Optimized supply chain

Qualified as AM
parts
Not originally
qualified as an
AM part
Whole Parts (Direct)
AM can
significantly
reduce time and
cost to produce
parts for sunset
programs
Whole Parts (Indirect)
Blade tip
welding and
other traditional
additive repairs
could be
performed with
greater precision
Repair
Additive manufacturing can be used to make MRO whole parts (direct or
indirect) and add features (i.e., additive repairs)
3/30/2017 14
MRO USES OF ADDITIVE MANUFACTURING
Source: GE, EOS

Example: Replacement Parts
3/30/2017 15
Source: ATR, MRO Network, Stratasys
 Interior cabin parts for sunset aircraft
 Often, old molds are unusable or a part is no longer available
 Previously a new mold would have to be made, costing
thousands of dollars.
 Minimum orders are usually in the hundreds in order to make
the part viable economically
 It is now possible to manufacture a single component,
reducing not only production costs, but also the warehouse
costs of storing 10+ years of excess parts ordered
Traditional Production Additive Manufacturing
Molds and techniques outdated Up to date technologies
Minimum order of 200 pieces Possible to manufacture a single part with no economic drawback
Long lead times
Manufactured in house: rapid iterative prototyping and final
component production can take weeks not months

Example: Prototyping and Tooling
3/30/2017 16
Source: MRO Weekly
Traditional Techniques New AM Techniques
Long lead times for each prototype Rapid prototyping can produce parts from cad designs in hours not
days
Machining and material costs drive up price of prototype Relatively cheap plastics and machine running costs mean
inexpensive prototypes are possible
 Air France Industries is already using additive manufacturing
for tooling and prototype design purposes
 Accurate prototypes can be used to test the fit of parts and
the speed of production combined with relatively low cost
promotes iterative design, with prototypes being refined and
re-printed methodically
 Final parts are then manufactured using conventional
techniques
 This process has been used to prototype a CF6 turbine rear
frame repair part as well as Boeing 787 seat track covers

Example: MRO Tooling – Safety Collar / Flap Immobilizer
3/30/2017 17
Source: Satair, MRO Newtork
 More freedom to manufacture tools additively as there are
fewer certifications needed
 Previously machined from a titanium block
 Topology optimization was used to determine where strength
is needed, and where material can be removed
 New design is half the weight, saving material and
promoting ease of use
 Satair have selected 60 other tools to be manufactured
additively
Traditional Production Additive Manufacturing
Heavy and bulky Light weight (50%) and slim design
Unnecessary material and wasted material during manufacture Topologically optimized to use minimum necessary material
Other disadvantages: Difficult to machine, sharp edges
Other benefits: Rounded corners and edges, increased ease of
use due to weight savings, looks good!

Example: Tailored Part Repair
3/30/2017 18
Source: Satair
 New research being done into customizable tailored part
repair. Applications would suit damaged turbine blades.
 3D scans of damaged parts combined with files containing
their original geometries allows the computer to calculate the
exact action needed to restore the part
 Direct metal deposition ‘fills in the gaps’ depositing metal
precisely where needed in order to match the physical part to
its original geometry
Needs a person to assess the damage and decide on action Computer can assess damage and plan repairs
Requires a skilled human to build weld by hand to restore part CNC machinery executes the repair to exact specifications

Example: Wing Repair
3/30/2017 19
Source: ATR
 ATR additively manufactured a patch to repair the leading
edge of a wing
 The patch was constructed from titanium for its strength and
weight advantages
 The patch was able to be manufactured to specification and
specific to the individual repair job, providing the support only
where required
 The part used less material and was subject to shorter lead
times in comparison to a machined alternative
Long lead times Shortened lead times
Generic solutions that require modification by hand Parts created specifically for the task, are completely compatible
with no modification required

Cold Spray (CS) repair process approved for military applications
3/30/2017 20
 Cold Spraying involves accelerating metal powder
to supersonic speeds
 The particles are ejected from a nozzle at a
substrate
 Upon impact with the substrate, the deformation of
the particles generates localised heat which welds
them to the surface
 Layers of cold spray can be applied in order to
build or rebuild a coating on the surface of a
component; like 3D painting
 It can also be used to regenerate a component that
has become worn down over time
Source: GE

RUAG has developed and obtained approvals for 40 cold spray repairs on
both fixed wing aircraft and helicopters
3/30/2017 21
Source: RUAG
RUAG is applying DMD technologies to coat and clad parts as well as create
3D printed near net parts with cold spray

Early application of additive manufacturing began to improve aftermarket
support to operators
3/30/2017 22
Source: Daily Mail, Airbus
RAF Tornado
 BAE producing protective covers
for cockpit radios and guards for
power take-off shafts to sustain
RAF Tornados via AM
 Parts first flew in December 2013
 These AM parts could cut RAF’s
maintenance costs by $1.9M over
four years
Air Transat A310
 In February 2014 the first AM
component – a small plastic crew
seat panel – flew on an Airbus
customer jetliner
 The aircraft was an A310 operators
by Air Transat
 Like most aircraft OEMs, Airbus is
working towards “on demand” spare
parts

OEMs and MROs are using additive manufacturing to build spare parts and
tools for mature and sunset platforms
3/30/2017 23
Source: Aviation Week, ICF Research
Struts, guards and
covers
UK Royal Air Force
Tornado GR4
BAE Systems
Support struts for air
intake doors
Protective guards for
power take-off shafts
Cockpit radio covers
Interior Parts
Various Aging
Aircraft
ST Aero
3D printing castings
for PMA interior parts
Decreases time to
develop molds
Breather Pipes
Regional Jets
BAE Systems
40% cost savings
compared to injection
molding
Recently received
EASA approval
Tooling
Various Aging
Aircraft
Advanced Composite
Structures
Additively
manufacturing tools
for the repair of
composite structures
Engine
Components
LEAP Engines
CFM
19 AM Fuel Nozzles
in each engine
Combines previously
18 parts into a single
piece
25% Lighter than
previous fuel nozzle

There are several critical barriers to adoption of additive manufacturing in
aerospace
3/30/2017 24
Source: ICF analysis
Additive
Manufacturing
Barriers
Engineering
Mind-set
Cost
Machine
Throughput
Materials
Development
Quality and
Repeatability
Qualification
and
CertificationCertification may be the
most critical barrier

For operators, additive manufacturing holds the promise of improved
aftermarket support
3/30/2017 25
Source: ICF
Operators of mature and sunset aircraft are often frustrated by long
lead times and excessive prices for OEM service parts
AM will also see widespread application for parts repairs; examples
include cold spray and turbine blade repairs
Additive manufacturing offers the potential of an aftermarket
paradigm shift for certain parts, collapsing lead times to a fraction of
current levels
As certification issues are addressed…AM may also be adopted by
PMA parts suppliers and MRO firms, offering greater choice to
operators

Thank You!
Peter Zimm
Principal
+1 347 843 9746
peter.zimm@icf.com

Aerospace & MRO Advisory Support
27
AEROSPACE & MRO
ICF guides manufacturers, airlines, independent MROs, suppliers, and the financial
community through every step of the aerospace and MRO supply chain to realize
value and deliver strategies that drive growth. We understand and focus on the key
aspects of the industry, and have the proprietary tools necessary for successful
operations. Below, we briefly describe our core aerospace & MRO services and
proprietary supporting products.
ICF focuses on
key aspects of the
industry that drive
value in both
revenue growth
and cost control.
Strategy Development
Leveraging years of aerospace and MRO
advisory experience as well as proprietary
market intelligence, ICF delivers data-driven,
objective insight to underpin
sustainable strategies.
Transaction Support
For clients’ investment decisions, ICF
combines global thought leadership in
aerospace and MRO supply chain with
accurate market intelligence, operations
expertise, and unparalleled industry contacts.
Operations and Supply Chain
ICF’s proven tools and methodologies offer
improved performance and cost reduction
across manufacturing, operations, and all
phases of make-buy supply chain planning
and execution.
MRO Business Improvement
For airlines, OEMs, and independent MROs,
ICF has deep experience in comprehensive
operational and financial diagnostics based on
extensive proprietary benchmarks, followed by
results-oriented improvement programs.
AEROSPACE & MRO PRODUCTS
ICF’s suite of proprietary
aerospace & MRO tools, models,
and databases helps stakeholders
navigate key business challenges
to their advantage.
Fleet &
MRO Forecasts
Aircraft Manufacturing
Database
MRO Best Practices
and Benchmarks
Proprietary, independent forecasts for
commercial and business aviation,
industrial gas turbine, and
military markets.
Production value breakdown by
component category and raw
material content across the
aerospace supply chain.
Comprehensive, proprietary databases
on processes, costs, and organization.
3/30/2017

Operations & Supply Chain Advisory Support
28
OPERATIONS & SUPPLY CHAIN
ICF offers an alternative cost reduction and performance improvement approach for
aerospace manufacturers. ICF’s small, experienced teams employ a focused method
to quickly target the greatest opportunities from a relevant set of facility data while
using minimal client resources. Once implemented, ICF’s recommendations maximize
improvement and drive meaningful, long-term, and sustainable gains to the company’s
bottom line.
ICF focuses on
key aspects of the
industry that drive
value in both
revenue growth
and cost control.
OPERATIONS & SUPPLY CHAIN
PRODUCTS
ICF’s suite of proprietary
operations & supply chain tools,
models, and databases help
stakeholders realize cost reductions
and performance improvements.
6 Step Diagnostic
Framework
Cost & Performance
Benchmarks
Aircraft Manufacturing
Database
A proven process that minimizes
disruption to you and your team while
maximizing actionable results from a
rapid assessment of operations and
supply chain activities
Proprietary benchmarks of multiple
cost categories and operations
metrics by part families, operation
types, and materials .
Production value breakdown by
component category and raw
material content across the
aerospace supply chain
• Supply chain maturity and supply chain
risks diagnostic
• Standardization of end-to-end supply
make/buy activities
• Evaluation of supplier performance &
improvement actions
Ops & Supply Chain Excellence
• Identification & management of cost
side drivers of the
income statement including overhead /
wrap rate
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purchase spend analytics
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to low cost countries
Cost Reduction
• S&OP maturity diagnostics including
ramp up readiness
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development through standardization
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additive manufacturing diagnostics
New Product Introduction
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procurement, engineering and other
factory support with clear identification
of margin risks and mitigation
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leverage for purchases
OSC Excellence
3/30/2017

Peter Zimm - MRO WORKSHOP - SPOTLIGHT: Additive manufacturing (3D printing) is expected to have a profound impact on global supply chains, including in the aviation industry. What does 3D printing mean for the future of manufacturers and MROs?

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