Additive manufacturing (AM), also known as 3D printing, is a process that creates physical objects by adding layers of material on top of each othe

November 2016
Airbus Emerging Technologies & Concepts ALM Overview
Emerging Technologies & Concepts
Peter SANDER
On the way to
Additive Manufacturing
Chances & Challenges for
the Future Design ,
Industrial Production
and Materials

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.
Emerging Technologies & Concepts
November 2016
ProtoSpace &
ProtoNet
ALM &
Bionic Design
Customer Driven
Innovation
(CeBIT 2014)
Page 2
Peter Sander, Dipl. Ing.
Airbus Hamburg
Manager Emerging Technologies &
Concepts Germany
35 Years Aircraft Industry
Indutrial Engineering
Tool design and manufacturing
Manufaction Engineering
Sheet Metal Production
CRFP Production Stade
A380 Operations
Airbus R&T since Oct. 2010

November 2016
On the way to Additive Manufacturing
Chances & Challenges for the Future Design , Industrial Production
and Materials
1 – Emerging Technologies & Concepts
 Way of Working
 internal & ww campaigns
2 - 3D Printing / ALM – an Overview
ALM activities WW (some..)
ALM Motivation
ALM Materials&Processes
3 - 3D Printing Platform Airbus
Demonstartor & Serial activities
Page 3

What is important within innovation ?
November 2016
Page 4
Innovation is the creation of better or more effective
products, processes and technologies that are accepted by
markets and society.

© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
November 2016
Discover the ease of flying
• The first intelligent travel accessory
for modern air travel experience
• Re-inventing baggage through
cross-industry collaboration
Customer Driven Innovation > BAG2GO > RIMOWA Electronic Tag
press@bag2go.aero
Page 5

November 2016
Customer Driven Innovation > BAG2GO > RIMOWA Electronic Tag
press@bag2go.aero
Page 6

How to find the Ideas and disruptive idea owners?
 Airbus Idea Space
Seite 7
November 2016
 Speed and individual help for disruptive idea´s and - owners

3D Printing Challenge on Idea-Space to find new ALM Ideas
November 2016
192 3D Printing Ideas collected in 5CW
GB / F / G / ES/ USA  2014
13 Finalists-Projects printed in 6 CW
and awarded September 05.th
(Sponsor G. Butschek / Y. Barbaux)
Page 8

Campaign Finalists
Ceremony Day of the Winners
3D Printing Challenge 2014
Find the best parts for 3-D printing
LZN September 05.th, the Finalists from GB/F/USA/G presented their ALM Projects
Empowered by
LZN &
Concept Laser
November 2016

Cars
Local Motors
November 2016
Page 10

Airbus
Cargo Drone Challenge
November 2016
Page 11
http://additivemanufacturing.com/2016/04/12/airbus-group-local-motors-launch-co-creation-challenge-to-rapidly-advance-development-of-commercial-drones/
AirBee
LZN/HSU

Drone Challenge
Airbus & Local Motors
November 2016
Page 12

November 2016
Page 13
1 – Emerging Technologies & Concepts
 Way of Working
 internal & ww campaigns
2 - Backbone Projects
- Customer driven Innovations
- Space Technologies for Airbus Aircrafts ?
- 3D Printing & Bionic Design
3 – Protospace im ZAL

ALM – AM – 3D Printing
Wohlers Report 2016, Market Growth
September 2016
Page 14
http://wohlersassociates.com/

Airbus Emerging Technologies & Concepts ALM Overview September 2016
Seite 15
Terry Wohlers Report 2016
http://www.wohlersassociates.com/

ALM
3D Printing in Space, house printing China
September 2016
Page 16
https://www.youtube.com/watch?v=SObzNdyRTBs
https://www.youtube.com/watch?v=XENDSqp-Oss
https://www.youtube.com/watch?v=d8JmuMbAcCE
10 printed houses in 1 day?

ALM
3D Printing of Houses
September 2016
Page 17
http://www.spiegel.de/fotostrecke/fotostrecke-luxus-haus-mit-pool-aus-dem-3d-drucker-fotostrecke-127252.html

ALM
3D Printing of Houses
September 2016
Page 18
http://www.stern.de/digital/technik/3d-drucker-dubai-gebaeude-6866668.html
Target Dubai: 2030  25% houses=printed
3D Printer: 6m x 36 m
250m² Building
17 day´s for printing
3 day´s for assembly
Cost: 140.000$

Maersk
On Board spare part cell
September 2016
Trend: Production on demand
Located at the point of use
http://3dprint.com/9021/maersk-ships-3d-printers/
Page 19

DB - activities
Spare part & maintenance product optimization
September 2016
Page 20
Kick Off
Berlin
June 29.th
2016
 400 parts
done

Cars
New light weight concepts, enabled by ALM
September 2016
Page 21

September 2016
http://www.zwomp.de/2014/03/25/zaha-hadid-yacht/
Page 22
Yacht - Shipbuilding
BuV futuristic design concept

ALM Airbus Group
Airbus Helicopters, NH90 Inconel exhaust noozle, 1. Flight April 1st 2014
July 2014
ETCG ALM 3D Printing Overview
Page 23

ALM
Aircraft APU Engine Activities Australia
August 2016
Page 24
Monash University and spin-out company Amaero Engineering on Concept X-Line 1000
http://www.gizmag.com/3d-printed-jet-engine/36273/
http://www.abc.net.au/news/2015-02-26/australian-researchers-create-first-3d-jet-engine/6262462

ALM
Satellites
Airbus Emerging Technologies & Concepts ALM Overview November 2016
Seite 25

ALM
Approaches USA, Space X
http://www.spacex.com/news/2014/07/31/spacex-launches-3d-printed-part-space-creates-printed-engine-chamber-crewed
November 2016
Seite 26

BIONIC_3d_printing
Web search & Overview
2013/02/06
Matthias Hegenbart
USA NASA
AM In space
September 2016
Page 27
Trend:
Production on demand
Located at the point of use
http://www.tctmagazine.com/3D-printing-news/made-in-
space-3d-prints-splash-down-on-earth/
with some tools and parts 3D printed on the ISS space station.

ALM
Aircraft Engine GE Activities
November 2016
Page 28
http://3dprinting.com/news/ge-aviation-gets-faa-certification-for-first-3d-printed-jet-engine-part/

ALM
Aircraft Engine GE Activities
November 2016
Page 29
http://www.gereports.com/airbus-gets-1st-production-jet-engines-with-3d-printed-parts-from-cfm//

November 2016
On the way to Additve Layer Manufacturing:
Chances & Challenges for the future industrial production
Agenda
2 - 3D Printing / ALM – an Overview
ALM activities WW (some..)
ALM Materials&Processes
Page 30

3D Printing “ALM”: Technologies
Film FDM Material Ultem (PEI) / LBM/EBM Mat. Ti/Inox/Al / HDR
Page 31
Page 31
+ HDR
Powder-
Wire-, &
Feed

November 2016
Airbus Emerging Technologies &
Concepts
Peter SANDER
ALM / 3D-Printing
Overview Future
Machine Development´s

Seite 33
Terry Wohlers Report 2016
Basis: 842 ind. Printer systems
http://www.wohlersassociates.com/
A M S Y S T E M S I N S T A L L E D 2 0 1 5

AM
Boeing Tooling
September 2016
Page 34
http://www.boeing.com/features/2016/08/record-books-08-16.page

September 2016
Airbus ALM/3D Printing
Trends – X-Axis FDM (Stratasys, Boeing, Ford, Siemens)
Page 35
https://www.youtube.com/watch?v=wDUMHFF-7vg

September 2016
EBM
Page 36

September 2016
Concept  X-Line 1000 and new X-Line 2000 Serial Printer
X-Line 2000: Volume: Laser Power
800x400x550 2x1000W (e.o. 2015)
Page 37
Complete
Closed
Double
place
system
3D Printing de-packing in parallel

September 2016
Trends – multifunctional machines
Page 38

September 2016
Trends – multifunctional machines
Page 39
Pinneberg
•Sicherheitskühlrohr: 1.4404
•Vakuumbauteil: Kombination von Kupfer (konventionelles Rohr)
und Edelstahl (additiv gefertigt) zu Multi-Material-Bauteil (Bimetalle)
•Wärmetauscher: additiver Aufbau und „Aufflanschen“, Aufbauen auf 3D-Geometrie (1.4404)

September 2016
AeroSud  aeroswift Project
Volume: Laser Power Max. Build up rate
2000x600x600 5KW 250cm³/h
First Demo Parts 2015
Serial Mode 2017  2013:
Page 40

September 2016
Future ALM shops
Page 41
Big need in future ALM Factory setups and designs

November 2016
Chances & Challenges for the future industrial production
Agenda
Page 42

ALM Platform
Jerome Rascol
September 2016
Page 43

ALM Design & Production in Praxis
4-day Training for Airbus Employees
September 2016
44
Trainings for 58 P. done
for 2015
Training 2016
 280
 2016: 280 to be trained

November 2016
Airbus Additive Layer Manufacturing
Germany
Ongoing ALM coops: Exchanges  Airbus-LZN Workshops
Page 45
We are very open to extend our network / ALM-Cooperation´s!

November 2016
Chances & Challenges for the
future industrial production
Agenda
Page 46

Future fast track product development by using ALM (1/2)
Page 47
• Polyamide-Alumide materials
• 90% lead time reduction
• 75% cost reduction
• Rapid analysis of future aircraft components
Wind tunnel tests
September 2016

September 2016
High Speed Development
Step 2:
Printed wind tunnel models
Page 48

Marc Fette
CTC
LZN/Concept
September 2016
ALM – 3D Printing
CFRP heatable tooling
Page 49

ALM – 3D Printing
Problem solving - missing part solutions – A350 wing high lift BRE
Edelstahl 1.4404 - Not flying Material  Availability demonstrated  2016 serial mode
Price LZN all 4 parts: 4.677,50 €.
September 2016
Seite 50
Christian Napp
A350 MAP Bremen
ESWAB2
AIRBUS
mobile: + 49 (0) 151 14048417
phone: + 49 (0) 421 538 5316
Video bearing function printed in 1 shot

September 2016
Flighttest - SA Test flight May 27.th – sucessfully passed!
ALM – 3D Printing
MPS1 – Ti Druckbehälter Actuator
Page 51
flown June 27th on A320.
The damper worked well, was removed after test flight

Material: Alu
 3D-Nesting tests
September 2016
A330 NEO FTI Metal
Page 52
Wing High Lift Bracket

September 2016
Pax & Emergency Exit
ALM – 3D Printing
A350 door approach
Page 53
First Flight
A350 MSN 002:
April, 02.nd 2015
Still in use

September 2016
Functional FDM Plastic parts
Page 54

September 2016
Engel, Joerg, 2 times
each
Airbus ALM / 3D Printing
Cabin Gobo light short term solution 11/2014
Page 55

First 3D Printed Spare Part at AIRBUS
A real out of production demonstrator  “Belt Mold”
ALM - Belt Mold
• purchase price/part: ~ $ 265,-*
• lead time: ~ 1 to 2 weeks
Request
AIRBUS Innovation Cell
Flying with Air TransNet
Feb 2014
September 2016
Trend:
Printing on Demand, at the point of use
Certified spare part printing cells
Instead of stocks (Frankfurt/Singapore..)
Seite 56

September 2016
Airbus Emerging Technologies & Concepts
ALM / 3D-Printing
Awards:
Finalist German Innovation Award Feb.14
German Design Award special mentioned in Gold Feb.15
Airbus ALM / 3D-Printing
First flight Bionic Cabin Bracket June 20.th

FCRC Cabin Bracket – Installation 2013
Bracket installed on FCRC Cabin Monument (TLS):
September 2016
Installed on A350 MSN 5
Task 2014: Weight Reduction 50% &
Industrialisation for serial production
2016 onwards
Seite 58

Benefits:
Production lead-time: - 25% FAL installation time: - 30%
Weight : - 49% (Target was >25%)
RC saving: 54% (Target was >20%)
Reduction of complexity:
A320 COCKPIT DOOR UPPER HINGE BRACKET
Why did the jury vote for it?
Reduction from 14 parts to 2 parts which has lead to:
production lead time, FAL installation time, weight and cost reduction and the very good maturity of the idea which
contributes to the A320 ramp up
Idea Owner(s): Joyce Tan, Martin Metten, Iwan Pangalila,
Bo Wang, Paul Lepkowski, David Will, Klaus von Varendorff
Short Description:
• A load-optimized Bracket
assembly consisting two parts.
• Part-A (connected permanently to
the A/C structure) and Part-B (for
installation of the Cockpit Door)
Material: Ti6-4
WINNER OF THE CATEGORY !!!
September 2016
Page 59

ALM / 3D Printing
Cabin Bracket
Airbus Emerging Technologies & Concepts ALM Overview September 2016
Impact tests successfully passed….
Page 60

Benefits:
Reducing the part count for the specific function from
currently 126+ items down to 1 (3).
Lead time reduction from 20 days to 2 days, weight reduction appr. 30%
Reduction of complexity:
Hydraulic Reservoir Rack (Assembly)
Why did the jury vote for it?
Reducing the part count for the specific function from currently 200+ items down to 1 for future big
size 3-D printing machine
Idea Space campaign winner, cluster reduction of complexity
Short Description:
• Hydraulic Reservoir Rack
Assembly consists of:
• 126 Drawing parts
• 27 Fastener
• 61 Anchor nut
Material: Al
September 2016
Page 61
Trend: ALM enables
126:3

ALM Manifold Approach
together with
September 2016
Status: TRL6,
Flyable on A380 Test AC, Dec. 2016
55% weight reduction
ALM – 3D Printing
Systems – A380 Spoiler Actuator Manifold  example for common ALM R&T
Page 62

A330Neo-900 FCAF FIN Tip goes 3D
November 2016
• New FIN Tip design
Page 63

ALM – 3D Printing
FTI trailing cone fin tip, one set of parts < 30 k€
November 2016
Page 64
Relevant cost & weight saving demonstrated

A330Neo-900 FCAF FIN Tip goes 3D
November 2016
Page 65

September 2016
Dents (1,2mm sheet metal)
Test: Reworking in PAG
Sheet metall shop (BRE-H57)
ALM – 3D Printing
Sheet Metal
Seite 66

September 2016
Trend:
No tooling needed
ALM sheet metal printing  CFRP
ALM – 3D Printing
Sheet Metal
Page 67

Airbus Emerging Technologies & Concepts
September 2016
Page 68
Learn out of nature & Print the future !
3 – Bionic Solution
Print the future

From Giant Victoria Water Lily to an Aircraft Spoiler
September 2016
Page 69

September 2016
Bionic Spoiler
Project
Bremen
Oliver Seack
First Outcome´s
Bionic Spoiler Demonstrator
Page 70
2m ALM Powderbed machine South Africa

Future Design & Production in Aviation – Bionic Partition
October 2016
Page 71

October 2016
Seite 72
TOPOLOGY OPTIMISATION AIRBUS
VISION 2050 ENABLER
Bionic AC Structures... ?

October 2016
ETCG Awards, Pess Review, Presentations & Events
Page 73
Hamburg CCH, October 11.th 2016, Airbus on stage:
Airbus Bionic Partition won the Component Award category AM

ALM ProtoNet Partners
And finalists Deutscher Zukunftspreis:
November 2016
74

November 2016
© Airbus S.A.S. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS. 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 S.A.S. 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 S.A.S. 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 75
Thanks for your Attention!
I like to extend my network on ALM!
peter.sander@airbus.com
Airbus 3D Printing Video on YouTube
http://www.youtube.com/watch?v=Cy3V3KR1LW
Download the new Airbus FAST Magazine with 3D Printing:
http://www.airbus.com/support/publications/?eID=maglisting_push&tx_maglistin
g_pi1%5BdocID%5D=42444
3D Printing Revolution:
http://www.harvardbusinessmanager.de/heft/
Nominiert für den Deutschen Zukunftspreis: „Eine Fertigungsrevolution hebt ab“
http://www.deutscher-zukunftspreis.de/de/nominierteDie Welt: Das sind die besten deutschen
Erfindungen 2015
Fokus 28/16 WIRTSCHAFT & GELD
Fliegen wie gedruckt
http://www.focus-magazin.de/

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