The Future of Aerospace Manufacturing

The last few decades have brought forth an almost compulsive form of streamlining to the manufacturing sector. Though it would be wise to consider this trend as the natural evolution of the sector at large, the quest for bigger and better technology does not always result in an increased overall efficiency. Today's world favours disruption over streamlining of existing technology, and rightfully so. A brand new disruptive technology that throws familiarity out the window will obviously garner more attention than a minor improvement on an existing process or system. This is why Additive Manufacturing or 3D Printing as it's commonly known, has thrown the entire industry into a spiral. In an industry that requires the precision fabrication of small batches of very complex components, Additive Manufacturing perfectly fits the bill. It isn't the most perfect way of doing things, but it's the next best thing.

This is why Additive Manufacturing is the future of Aerospace Manufacturing.

Designs are no longer limited by complexity

The next big thing isn't about going bigger, but rather going smaller. Ironically, his has a lot to do with the huge scale of the aerospace industry. What might seem like a superficial improvement can result in millions of dollars of savings overtime. Perhaps, this is why the new CFM LEAP engine produced jointly by long standing partners GE and Snecma will have 19 fuel nozzles, all manufactured using Additive Manufacturing techniques.

Failure hurts a little less

Traditional manufacturing methods call for the inclusion of a failure buffer in the original project budget. This means that a significant part of the budget is allocated towards mopping up mistakes and serving as a safety harness. Now to be fair, it's impossible to do away with the "Failure Fund" but Additive Manufacturing or Rapid Prototyping (as it's commonly known in these circles) serves to dampens the damage on the project budget. Traditional Manufacturing methods call for not only the manufacturing of the prototype but also for the manufacturing of support equipment such as jigs, toolings and fixtures. That is why Additive Manufacturing works so well with prototyping as it can be used to manufacture multiple prototype variants, minus the expensive support equipment and crushing tooling costs.

Simplification of processes

Additive Manufacturing takes the complexity out of the machining process. The human element in Additive Manufacturing leans heavily towards the design and not the actual manufacturing process. As of now, most Additive Manufacturing methods require moderate to heavy post processing. However, with the advancement of both Additive Manufacturing software and hardware, the surface finish will continually improve to the point where the required post processing on the component is very minimal. This technology also works towards automation, thereby limiting the parameters for human error.

Supply Chain disruption

Additive Manufacturing poses a significant disruption in the supply chain. The aerospace supply chain of today's world is one of the most expansive systems, linking Tier -1, Tier - 2 and Tier - 3 suppliers all across the world to assembly plants and customers. This equilibrium of this network is kept in order by series of robust logistics and shipping companies. Now this rigid network works great when it comes to manufacturing and even scheduled MRO. However, it doesn't always work out great for the average bush pilot who has to wait for the required component to run the supply chain gauntlet. It may take weeks or even months before the component reaches his or her remote Alaskan town.

Now imagine if said bush pilot didn't have to wait for weeks or even days to get his or her bird back in the sky. This is what Additive Manufacturing can bring to the end user. The pilot would have to drive down to the nearest Additive Manufacturing setup with nothing more than a CAD file of the component and wait for a few hours for the component to get fabricated. The effects of this technology are far reaching and significant especially for users such as the military, who operate out of remote Forward Operating Bases across the world, or aircraft carriers at sea. Even the International Space Station has a 3D printer aboard. The applications seem to be unlimited.

Are we there yet?

Since Additive Manufacturing is the future of Aerospace Manufacturing, are we seeing large scale adoption in the sector?

Yes and no. Yes because most aerospace firms have either already invested in Additive Manufacturing or are seriously considering doing so. No because its use is mostly restricted to prototyping (apart from a few noteworthy examples). But before drawing conclusions, let's not forget that Additive Manufacturing as we know it today began gaining traction only in the early 2000s. Significant investment in technology with simultaneous, steady implementation is a winning combination, especially when the technology in question has already been tested and proven.

Continued relevance of conventional manufacturing

So does this spell the end for conventional manufacturing? Definitely not. It still makes more sense to fabricate large aerostructures using metal alloys and composite materials. Metal castings and forged components aren't going anywhere soon. The airframe of the future will be a hybrid structure that combines the familiarity of metal alloys with the strength of light weight composites and the constraint free manufacturing methods of Additive Manufacturing. The possibilities are simply endless.