The document discusses the challenges of timely delivery and quality of drilling grids for Airbus's A380 assembly, highlighting the potential of 3D printing and topology optimization as a solution. It proposes using additive layer manufacturing to create lighter, faster, and more efficient drilling templates, significantly reducing production time from 12 weeks to 2 weeks. The method allows for local printing and easier implementation, making it a practical alternative for tooling requests.

1. Agile Drilling Template
definition and production
• Topology optimization
• Additive Layer Manufacturing
September 2015
AIRBUS – Saint-Nazaire plant
Presented by Sebastien HAUDRECHY
Co-author: Julie QUEROIS
Abstract: Due to recurrent lack of on time delivery of Drilling grid
(made of a 2cm thick aluminum pad), 3D printing can potentially
propose an alternative enlightened solution in 3D printing
(topology optimization).

2. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
Introduction
2
Major Component Assembly Breakdown of a A380 Saint-Nazaire plant activities: assembly, equipment and
testing of front and centre fuselage sections for the entire
Airbus family
Use of drilling templates for best accuracy and hole
quality (associated with relevant drilling machine)
Number of
Drilling
templates
delivered in
2014
September 2015

3. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
What is a drilling grid?
3
Current Drilling
grid design
Currently all Drilling templates are machined in :
• 2017A (AlCu4MgSi) for all drilling templates machined in 3 AXIS
• 7075 (AlZn55MgCu) for all drilling templates machined in 5 AXIS
September 2015

4. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
Problem definition
4
Missing drilling grid can occur due to:
• Late definition/modification by design office
• Impossible repairing after defective status
• Fatigue impact on quality
In that case, reordering needs a standard average
delivery time of 12 weeks in order to get the
replacing grid.
In parallel, grids can reach up to 50kg handled by
only one operator in the worst ergonomics
conditions (for example: under the aircraft
fuselage…)
September 2015

5. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
Proposal
5
Printing locally an alternative enlighten drilling grid by using ALM approach
September 2015

6. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
Analysis
6
September 2015
Original part capacity check

7. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
The method(1/2)
7
First, extract the drilling points direction and type:
Use of specific
knowledge
templates On-demand
Implementation
September 2015

8. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
8
The method(2/2)
then, according to loading case, launch an optimization in order
to get minimum material consumption:
Model simplification
(CV5 or Evolve)
Check analysis
of model
Material
mechanical
properties
September 2015

9. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
Result
9
Time saving: 6 times faster
• Classical delivery time: 12 weeks
• Printed version delivered within only 2 weeks
after ordering launch
Drilling grid printed by SLM (Selective Laser Melting)
Price: 1.4 * original price
Weight saving: 70% lighter
• Original weight : 1020 g
• Printed grid weight: 300g
Actual parts comparison
September 2015
Virtual parts
comparison

10. © AIRBUS Operations S.A.S. All rights reserved. Confidential and proprietary document.
Conclusion
• Rapid method for agile alternative design
• Applicable on any new tooling request
• Easy to implement (properties and knowledge
embedded in the method)
• Production time highly decreased
• Local printing if possible
• Easy sub-contracting request
• ALTAIR INSPIRE and EVOLVE
• Local software installation: no need of remote
calculation service
• User-friendly: for the tooling definition, no need of
high stress competencies
10
September 2015