Quality-assured additive manufacturing of load-bearing aerospace components

Purpose and goal

The aim is to validate a recently developed control system for additive manufacturing of aircraft structures. In particular its ability to detect possible defects during the production process and limit their occurrence and size through closed-loop process control. The goal is to enable a greater use of additive manufacturing for aircraft systems and thereby strengthen the Swedish aviation industry. The project´s results are valuable for both aircraft structures and aeroengine components.

Expected effects and result

Higher proportion of AM results in reduced need for virgin materials compared to conventional manufacturing. Components can be optimized for higher operating temperature, longer life or lighter weight. Reduced environmental impact throughout the product´s life cycle and lowered threshold for hybridization or electrification of aviation. More local processing is also possible due to reduced need for larger forgings, which provides a resilient and robust Swedish aerospace ecosystem.

Planned approach and implementation

The project is a collaboration between Procada and Linköping University and is divided into 5 work packages: Demonstrator design, Process development and fabrication concept, Demonstrator manufacturing, Mechanical and material testing and characterization, and Administration and dissemination. Demonstrator definition is done in consultation with Saab Aeronautics. To meet the requirements of a TRL5 review, demonstrator construction is done in production-grade AM equipment at PTC in Trollhättan.