3D Printing in Aviation Industry
The transformative impact of 3D Printing for Aviation
3D printed aircraft parts in Windform are supporting new generation of sustainable aero engines.
We are a trusted supplier of premium materials and additive manufacturing services to the global aerospace and aviation industry. By providing a one-to-one comprehensive service we are flexible enough to cater to the rigorous demands of diversified aircraft projects assisting in every phase of the development.
We support optimizing designs for additive manufacturing, streamlining assembly processes, and crafting exceptional aerodynamic components.
Flying towards efficiency. Reduced Weight, Noise Frictions.
Our cutting-edge materials, Windform XT 2.0 reinforced with Carbon fiber and Windform GT reinforced with glass fiber, have been instrumental in developing highly efficient components for the world’s largest aero-engine technology.
In aircraft engines with diameters exceeding 350 centimeters, our additively manufactured components have achieved a remarkable 10% reduction in weight, friction, noise, and emissions.
Windform additive manufacturing technology offers the potential to create demanding components of diversified size and features counting on 12 dedicated materials for high stress components offering extended safety and durability.
Part consolidation
Additive manufacturing with advanced Carbon and Glass Fiber composites allows us to consolidate multiple components into a single part, significantly reducing assembly time and streamlining the supply chain.
Parts’ consolidation in lightweight Windform materials contributes to greater efficiency and reduced emissions, enabling aircraft manufacturers to achieve sustainability goals that were previously unattainable through traditional manufacturing methods.
The Challenge
Realizing large size panels and components accomplishing the rigid EN9100 Aerspace standards as well as the latest requirements of efficiency and net zero flight targeted by 2050 and manufacturing complex and intricate shapes difficult to achieve with traditional manufacturing methods.
Our Solution
The components were selective laser sintered using an advanced carbon fiber composite Windform XT2.0 that, combined with sections realized in glass-fiber composite Windform GT, brought a huge improvement in the current engine’s design geometries providing for:
Multiple parts consolidation
A substantial increase in strength and resistance to air pressure, shocks, and harsh weather conditions
Ensuring long-lasting performance
Significant noise and friction reductions
Enhancing passenger comfort and reducing maintenance costs
A remarkable 10% weight reduction
Contributing to improved fuel economy and performance
Mechanical Achievements Beyond Expectations
Windform Carbon and Fiber Glass composites boast an unparalleled strength-to-weight ratio. They have undergone rigorous testing under extreme conditions, including vibrations, high and low temperatures, traction, impact according to Izod and Charpy testing conditions and have consistently demonstrated exceptional performances.
To ensure the highest standards of quality and safety, we implement stringent testing and inspection procedures throughout the additive manufacturing process.
- Advanced scanning technologies are used to verify the dimensional accuracy of printed parts, while non-destructive testing identifies potential defects
- Our extensive testing and safety procedures adhere to EN9100 certification requirements, providing the aerospace industry with pre qualified materials and components
Additional Materials testing on your specific needs’ is conducted to guarantee that the mechanical properties of printed parts meet the required project committments such as tensile strength, elastic modulus, impact resistance, and others that may be required by you.
Safety considerations are paramount, and we ensure that Windform materials comply with safety regulations and standards for fire resistance, heat resistance, durability.
Key engineering achievements include
Advanced carbon or glass fiber reinforcement
For components operating effectively at high air pressures and extreme temperatures
Utmost strength and lightness for the Sustainable aircraft of the future
Resulting in reduced Noise, Weight, and Fuel consumption
Quick parts reiteration
Including replacement of obsolete spares
Facilitated compliance and deployment
By prequalified, reliable, high-quality materials
Modular and highly customizable parts
For Complexity and Performance Optimization in terms of aerodynamics and functionality
Enhanced design for efficient parts
By consolidating more components in one
Cut costs, boost performances
From blueprint to takeoff Additive manufacturing in Windform lets you produce aviation systems, jigs and fixtures more quickly and cost efficiently than with traditional manufacturing, without sacrificing performances and quality.
Functional prototyping provides for durable components that can withstand rigorous testing, enabling rapid iteration of designs during product development.
3D printed functional components and systems not only eliminate tooling costs but also realize up to 80% cost savings due to their rapid implementation, part consolidation, and almost labor-free manufacturing.