Injectors are widely used in the Aerospace industry for fluid transportation. The varying use cases — depending on their needs — require a significant level of customization. Because of this, they are produced in large numbers and kept in storage as backups. This avoids long lead times of up to 20 weeks in case of failure and guarantees uptime for a part crucial to the company’s capital.

1. Objectify Technologies
Pvt. Ltd.
Case Study :
Ideate | Design | Create
The creation of a cutting
edge AM built injector for
the Aerospace Industry

2. Our client required a robust injector that would
push the limits of design and functionality. We
have made a lighter, more efficient, AM-built
application that opens up new opportunities to
leverage existing expertise

3. Injectors are widely used in the Aerospace industry
for fluid transportation. The varying use cases —
depending on their needs — require a significant
level of customization. Because of this, they are
produced in large numbers and kept in storage as
backups. This avoids long lead times of up to 20
weeks in case of failure and guarantees uptime for a
part crucial to the company's capital.
The Challenge

4. With additive manufacturing, applications can be
printed on demand, reducing waste from having to
overproduce to make things financially viable. This
also reduces lead times, and the need for storage can
be minimized through digital inventories, on-premises
manufacturing, and higher part-performing parts. In
addition, additive manufacturing can disclose new
business models and solutions in the spare parts
business, such as cutting out prototyping by casting
Solution

5. The Injector built up by means of traditional
technology was typically characterized by a large
number of parts, joined together through the
welding or brazing process.
Technological Aspects: Benefits of
DMLS in Injector Manufacturing

6. 80 about single elements
Brazing joint in the critical joint
(fuel/oxidizer interface);
Welding joints for the internal parts to be
joined.
1 single elements
No brazing joints in the critical joint. So no
leak of any propellants
No welding joints, that can represent a weak
point of the structure;
A typical product was so composed:
The innovative 3D Printed Injector are
instead composed of:

7. The main reasons for applying
Additive Manufacturing in the
Serospace components
manufacturing, instead of
traditional technology, are further
explained:
Increase Performance
Reduce mass (lightweight construction,
resource efficiency);
Increase efficiency (combustion processes, free
formed surfaces/channels);
Integrate closed, complex internal channels (e.g.
injectors geometry);

8. Integration of numerous functions in one single
component without assembly efforts;
Even complex objects will be manufactured in
one process step;
No need for special tools: direct production
possible without costly and time-consuming
tooling;
No need for long-lead procurement of billet
material;
Simplify Production and Increase
Production Safety
Rapid Manufacturing

9. Allow the alternative design / manufacture of
parts requiring machining of more than 80 % of
the initial material;
Increasing object complexity will increase
production costs only marginally.
Complex Shaped Parts

10. The choice of material, Ti6Al4V Eli (Titanium
alloy), is a suitable selection due to its
lightweight strength, and excellent resistance to
corrosion and temperature. It is commonly used
in aerospace applications like aircraft jet
engines and spacecraft due to its ability to
reduce fuel costs
Materials for AM built injector -
Ti6Al4V Eli
Powder Titanium Alloy Ti6Al4V

11. Objectify Technologies demonstrates a
commitment to quality and compliance by
obtaining relevant certifications and labels.
Specifically, the AS9100D certification is crucial
for aerospace and defense companies, as it
ensures adherence to stringent quality
standards, crucial in industries where equipment
failure can have severe consequences.
Inspections, Quality Control, and
Certifications

12. The Facts
Using Direct Metal Laser Sintering (DMLS) technology,
Objectify Technologies produce a single-piece
injector without brazing or welding joints, making it
more robust and eliminating potential weak points.
Objectify Technologies successfully built the injector
on the EOS M400-4 in its application center in India.
www.objectify.co.in
011-42418286 (Delhi) | +91 9437169133 (Noida)
marketing@objectify.co.in