Cutting costs and material use in an aerospace project

Cutting Costs and Material Use in an Aerospace Project

Case study developed by Université de Bordeaux and Institut de Mécanique et d'Ingénierie de Bordeaux (I2M).

Researchers at the I2M laboratory specialize in Additive Manufacturing (AM), particularly metal 3D printing processes. Teachers in the BUT graduate programme at the University of Bordeaux focus on design and manufacturing processes.

The core objectives include ensuring robust process control and advancing innovative approaches for learning and manufacturing. Working extensively with metallic AM systems, this team strives to enhance efficiency and reliability for a variety of applications.

Achieving the same properties with less material

The aim was to design and fabricate a lightweight yet structurally robust tripod for aerospace that significantly reduces material usage while maintaining the necessary mechanical properties. The optimization process used topology optimization algorithms to create a complex geometry, removing excess material in non-critical areas without compromising the component's strength.

This approach is highly beneficial for aerospace applications, where every gram of weight saved translates to improved fuel efficiency and performance.

How does Meltio's W-LMD contribute?

The decision to adopt Meltio's wire-laser metal 3D printing solution, specifically the new Meltio M600, stems from its notable advantages in cost-effectively producing high-quality metal parts. By using wire rather than powder as the feedstock, the system increases material utilization, lowers costs, and promotes a safer working environment.

Additionally, the hybrid wire-laser approach provides strong mechanical properties and high deposition rates, making it particularly suitable for industrial applications. Research efforts also involve in-situ monitoring of surface machining and examining microstructural quality through post-mortem analyses.

• Cost effectiveness
• High quality parts
• Shorter lead times
• Safer work environment
• Strong mechanical properties
• High deposition rates
• Suitable for industrial applications
• Microstructural quality

An optimized component topology

• 35% reduction in material use.
• 10.5x faster production time.

At a glance

• System: Meltio M600
• Sector: R&D and aerospace
• Material: Stainless steel
• Printing time: 5h 34min
• Production time: 3 weeks

Adopting Meltio in the R&D sector

In the context of this research environment, Meltio's platform cuts production costs by reducing material consumption and shortening lead times. From a scientific standpoint, the technology facilitates explorations into geometries and material combinations previously inaccessible, driving progress in functional gradient materials and lightweight structures.

This innovative use of additive manufacturing for topology optimization showcases how universities can push the boundaries of aerospace engineering, offering the potential for more efficient, cost-effective, and high-performance components in the aviation industry.

This case study was originally published by Meltio as Cutting costs and material use in an aerospace project, developed by Université de Bordeaux and Institut de Mécanique et d'Ingénierie de Bordeaux. Reproduced here with credit to Meltio.