An integrated design process for lightweight AM products using the DED process

Start Page
33
End Page
47
Citation
Innovative Product Development by Additive Manufacturing 2023
Contribution to Conference
Innovative Product Development by Additive Manufacturing 2023  
Publisher DOI
10.1007/978-3-662-69327-8_3
Publisher
Springer
ISBN of container
978-3-662-69327-8
978-3-662-69326-1
One challenge facing aviation today is the reduction of greenhouse gases. By reducing the weight of the aircraft, fuel consumption and the associated emissions can be reduced. For aircraft cabin interiors so-called sandwich structures are established. A major issue with these sandwich constructions is the load introduction, often causing over dimensioning, which counteracts the desired lightweight goals. Additive manufacturing offers new possibilities for structural design and customisation due to its design freedom. By using the Direct Energy Deposition process, which only requires a local inert gas atmosphere, components with large dimensions are feasible. However, this manufacturing process results in great challenges regarding accuracy, manufacturability, e.g. the use of closed cross-sectional profiles and the positioning of the build platform. In this paper a process to tackle these issues is developed. Applying the developed process, a design of a cabin partition is developed. From this design, bending specimens are derived, manufactured and tested to evaluate the feasibility and validate simulation models. It emerges that circular cross-sections in particular should be preferred for the next cabin partition design.
DDC Class
620: Engineering