AIRBUS Aditive Manufacturing

Airbus Emerging Technologies & Concepts ALM Overview November 2016
Emerging Technologies & Concepts
Peter SANDER
On the way to
Additive Manufacturing
Chances & Challenges for
the Future Design ,
Industrial Production
and Materials
Emerging Technologies & Concepts
ALM &
Bionic Design
Customer Driven
Peter Sander, Dipl. Ing.
Airbus Hamburg
Innovation
Manager Emerging Technologies & (CeBIT 2014)
Concepts Germany
35 Years Aircraft Industry

Indutrial Engineering
Tool design and manufacturing
Manufaction Engineering ProtoSpace &
Sheet Metal Production
CRFP Production Stade
ProtoNet
A380 Operations
Airbus R&T since Oct. 2010
Page 2
© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

On the way to Additive Manufacturing

Chances & Challenges for the Future Design , Industrial Production
and Materials
1 – Emerging Technologies & Concepts

 Way of Working
 internal & ww campaigns
2 - 3D Printing / ALM – an Overview

ALM activities WW (some..)
ALM Motivation
ALM Materials&Processes
3 - 3D Printing Platform Airbus

Demonstartor & Serial activities
Page 3

What is important within innovation ?
Innovation is the creation of better or more effective

products, processes and technologies that are accepted by
markets and society.
Page 4

Customer Driven Innovation > BAG2GO > RIMOWA Electronic Tag
Discover the ease of flying

• The first intelligent travel accessory
for modern air travel experience
• Re-inventing baggage through
cross-industry collaboration
Page 5
© AIRBUS Operations GmbH. All rights reserved. Confidential and proprietary document.
press@bag2go.aero
Customer Driven Innovation > BAG2GO > RIMOWA Electronic Tag
Page 6
press@bag2go.aero
How to find the Ideas and disruptive idea owners?

 Airbus Idea Space
 Speed and individual help for disruptive idea´s and - owners

Seite 7

3D Printing Challenge on Idea-Space to find new ALM Ideas
192 3D Printing Ideas collected in 5CW
GB / F / G / ES/ USA  2014
13 Finalists-Projects printed in 6 CW
and awarded September 05.th
(Sponsor G. Butschek / Y. Barbaux)
Page 8

Campaign Finalists
Ceremony Day of the Winners
3D Printing Challenge 2014
Find the best parts for 3-D printing
LZN September 05.th, the Finalists from GB/F/USA/G presented their ALM Projects
Empowered by
LZN &
Concept Laser
Cars
Local Motors
Page 10

Airbus AirBee
Cargo Drone Challenge LZN/HSU
http://additivemanufacturing.com/2016/04/12/airbus-group-local-motors-launch-co-creation-challenge-to-rapidly-advance-development-of-commercial-drones/
Page 11

Drone Challenge
Airbus & Local Motors
Page 12

1 – Emerging Technologies & Concepts

 Way of Working
 internal & ww campaigns
2 - Backbone Projects
- Customer driven Innovations
- Space Technologies for Airbus Aircrafts ?
- 3D Printing & Bionic Design
3 – Protospace im ZAL
Page 13

Airbus Emerging Technologies & Concepts ALM Overview September 2016
ALM – AM – 3D Printing
Wohlers Report 2016, Market Growth
http://wohlersassociates.com/
Page 14

Terry Wohlers Report 2016
http://www.wohlersassociates.com/
Seite 15

ALM
3D Printing in Space, house printing China
10 printed houses in 1 day?
https://www.youtube.com/watch?v=d8JmuMbAcCE
https://www.youtube.com/watch?v=SObzNdyRTBs
https://www.youtube.com/watch?v=XENDSqp-Oss
Page 16

ALM
3D Printing of Houses
http://www.spiegel.de/fotostrecke/fotostrecke-luxus-haus-mit-pool-aus-dem-3d-drucker-fotostrecke-127252.html
Page 17

ALM
3D Printing of Houses
Target Dubai: 2030  25% houses=printed

3D Printer: 6m x 36 m
250m² Building
17 day´s for printing
3 day´s for assembly
Cost: 140.000$
http://www.stern.de/digital/technik/3d-drucker-dubai-gebaeude-6866668.html
Page 18

Maersk
On Board spare part cell
http://3dprint.com/9021/maersk-ships-3d-printers/
Trend: Production on demand
Page 19

Located at the point of use
DB - activities
Spare part & maintenance product optimization
Kick Off
Berlin
June 29.th
2016
 400 parts
done
Page 20

Cars
New light weight concepts, enabled by ALM
Page 21

Yacht - Shipbuilding
BuV futuristic design concept
http://www.zwomp.de/2014/03/25/zaha-hadid-yacht/
Page 22

ETCG ALM 3D Printing Overview July 2014
ALM Airbus Group

Airbus Helicopters, NH90 Inconel exhaust noozle, 1. Flight April 1st 2014
Page 23

Airbus Emerging Technologies & Concepts ALM Overview August 2016
ALM
Aircraft APU Engine Activities Australia
Monash University and spin-out company Amaero Engineering on Concept X-Line 1000
http://www.gizmag.com/3d-printed-jet-engine/36273/
http://www.abc.net.au/news/2015-02-26/australian-researchers-create-first-3d-jet-engine/6262462
Page 24

ALM
Satellites
Seite 25

ALM
Approaches USA, Space X
http://www.spacex.com/news/2014/07/31/spacex-launches-3d-printed-part-space-creates-printed-engine-chamber-crewed
Seite 26

USA NASA
AM In space
BIONIC_3d_printing
Web search & Overview
2013/02/06
Matthias Hegenbart
with some tools and parts 3D printed on the ISS space station.
http://www.tctmagazine.com/3D-printing-news/made-in- Trend:
space-3d-prints-splash-down-on-earth/ Production on demand
Located at the point of use
Page 27

ALM
Aircraft Engine GE Activities
http://3dprinting.com/news/ge-aviation-gets-faa-certification-for-first-3d-printed-jet-engine-part/
Page 28

ALM
Aircraft Engine GE Activities
http://www.gereports.com/airbus-gets-1st-production-jet-engines-with-3d-printed-parts-from-cfm//
Page 29

On the way to Additve Layer Manufacturing:

Chances & Challenges for the future industrial production
Agenda
2 - 3D Printing / ALM – an Overview

ALM activities WW (some..)
ALM Materials&Processes

Page 30

3D Printing “ALM”: Technologies

Film FDM Material Ultem (PEI) / LBM/EBM Mat. Ti/Inox/Al / HDR
+ HDR
Powder-
Wire-, &
Feed
Page 31
Page 31
Airbus Emerging Technologies &

Concepts
Peter SANDER
ALM / 3D-Printing
Overview Future
Machine Development´s
Terry Wohlers Report 2016
A M S Y S T E M S I N S T A L L E D 2 0 1 5
Basis: 842 ind. Printer systems

http://www.wohlersassociates.com/
Seite 33

AM
Boeing Tooling
http://www.boeing.com/features/2016/08/record-books-08-16.page
Page 34

Airbus ALM/3D Printing

Trends – X-Axis FDM (Stratasys, Boeing, Ford, Siemens)
https://www.youtube.com/watch?v=wDUMHFF-7vg
Page 35


EBM
Page 36


Concept  X-Line 1000 and new X-Line 2000 Serial Printer
X-Line 2000: Volume: Laser Power
800x400x550 2x1000W (e.o. 2015)
3D Printing de-packing in parallel
Complete
Closed
Double
place
system
Page 37


Trends – multifunctional machines
Page 38


Trends – multifunctional machines
Pinneberg
•Sicherheitskühlrohr: 1.4404
•Vakuumbauteil: Kombination von Kupfer (konventionelles Rohr)
und Edelstahl (additiv gefertigt) zu Multi-Material-Bauteil (Bimetalle)
•Wärmetauscher: additiver Aufbau und „Aufflanschen“, Aufbauen auf 3D-Geometrie (1.4404)
Page 39


AeroSud  aeroswift Project
Volume: Laser Power Max. Build up rate

2000x600x600 5KW 250cm³/h
First Demo Parts 2015
Serial Mode 2017  2013:
Page 40


Future ALM shops
Big need in future ALM Factory setups and designs
Page 41


Chances & Challenges for the future industrial production
Agenda
Page 42

ALM Platform
Jerome Rascol
Page 43

ALM Design & Production in Praxis

4-day Training for Airbus Employees
Trainings for 58 P. done

for 2015
Training 2016
 280
 2016: 280 to be trained
44

Airbus Additive Layer Manufacturing

Germany
Ongoing ALM coops: Exchanges  Airbus-LZN Workshops
We are very open to extend our network / ALM-Cooperation´s!
Page 45


Chances & Challenges for the
future industrial production
Agenda
Page 46

Airbus Emerging Technologies & Concepts
September
ALM Overview
2016
Future fast track product development by using ALM (1/2)
Wind tunnel tests
• Polyamide-Alumide materials
• 90% lead time reduction
• 75% cost reduction
• Rapid analysis of future aircraft components
Page 47


High Speed Development
Step 2:
Printed wind tunnel models
Page 48

ALM – 3D Printing
CFRP heatable tooling
Marc Fette
CTC
LZN/Concept
Page 49

ALM – 3D Printing
Problem solving - missing part solutions – A350 wing high lift BRE
Christian Napp
A350 MAP Bremen
ESWAB2
AIRBUS
mobile: + 49 (0) 151 14048417
phone: + 49 (0) 421 538 5316
Video bearing function printed in 1 shot
Edelstahl 1.4404 - Not flying Material  Availability demonstrated  2016 serial mode
Price
Seite 50 LZN all 4 parts: 4.677,50 €.
ALM – 3D Printing
MPS1 – Ti Druckbehälter Actuator
Flighttest - SA Test flight May 27.th – sucessfully passed!
flown June 27th on A320.

The damper worked well, was removed after test flight
Page 51


A330 NEO FTI Metal
Wing High Lift Bracket
Material: Alu
 3D-Nesting tests
Page 52

ALM – 3D Printing
A350 door approach
Pax & Emergency Exit
First Flight
A350 MSN 002:
April, 02.nd 2015
Still in use
Page 53


Functional FDM Plastic parts
Page 54

Airbus ALM / 3D Printing

Cabin Gobo light short term solution 11/2014
Engel, Joerg, 2 times

each
Page 55

First 3D Printed Spare Part at AIRBUS

A real out of production demonstrator  “Belt Mold”
ALM - Belt Mold
• purchase price/part: ~ $ 265,-* AIRBUS Innovation Cell
• lead time: ~ 1 to 2 weeks
Flying with Air TransNet

Feb 2014
Trend:
Printing on Demand, at the point of use
Certified spare part printing cells
Instead of stocks (Frankfurt/Singapore..)
Request
Seite 56

Airbus ALM / 3D-Printing

First flight Bionic Cabin Bracket June 20.th

ALM / 3D-Printing
Awards:
Finalist German Innovation Award Feb.14
German Design Award special mentioned in Gold Feb.15

FCRC Cabin Bracket – Installation 2013
Bracket installed on FCRC Cabin Monument (TLS):
Installed on A350 MSN 5

Task 2014: Weight Reduction 50% &
Industrialisation for serial production
2016 onwards
Seite 58

Reduction of complexity: Material: Ti6-4

A320 COCKPIT DOOR UPPER HINGE BRACKET
Idea Owner(s): Joyce Tan, Martin Metten, Iwan Pangalila,
Bo Wang, Paul Lepkowski, David Will, Klaus von Varendorff
Short Description:
• A load-optimized Bracket
assembly consisting two parts.
• Part-A (connected permanently to
the A/C structure) and Part-B (for
installation of the Cockpit Door)
Benefits:
Production lead-time: - 25% FAL installation time: - 30%
Weight : - 49% (Target was >25%)
RC saving: 54% (Target was >20%)
Why did the jury vote for it?
Reduction from 14 parts to 2 parts which has lead to:
production lead time, FAL installation time, weight and cost reduction and the very good maturity of the idea which
contributes to the A320 ramp up
Page 59
WINNER OF THE CATEGORY !!!
ALM / 3D Printing
Cabin Bracket
Impact tests successfully passed….
Page 60

Reduction of complexity:
Hydraulic Reservoir Rack (Assembly) Material: Al
Idea Space campaign winner, cluster reduction of complexity

Short Description:
• Hydraulic Reservoir Rack
Assembly consists of:
• 126 Drawing parts
• 27 Fastener
• 61 Anchor nut
Benefits:
Reducing the part count for the specific function from
currently 126+ items down to 1 (3).
Lead time reduction from 20 days to 2 days, weight reduction appr. 30%
Why did the jury vote for it?
Reducing the part count for the specific function from currently 200+ items down to 1 for future big
size 3-D printing machine Trend: ALM enables
Page 61 126:3
ALM – 3D Printing
Systems – A380 Spoiler Actuator Manifold  example for common ALM R&T
ALM Manifold Approach

together with
55% weight reduction
Status: TRL6,
Flyable on A380 Test AC, Dec. 2016
Page 62

A330Neo-900 FCAF FIN Tip goes 3D
• New FIN Tip design
Page 63
ALM – 3D Printing
FTI trailing cone fin tip, one set of parts < 30 k€
Relevant cost & weight saving demonstrated

Page 64
A330Neo-900 FCAF FIN Tip goes 3D
Page 65

ALM – 3D Printing
Sheet Metal
Dents (1,2mm sheet metal)

Test: Reworking in PAG
Sheet metall shop (BRE-H57)
Seite 66

ALM – 3D Printing
Sheet Metal
Trend:
Page 67
No tooling needed
ALM sheet metal printing  CFRP
Learn out of nature & Print the future !
3 – Bionic Solution
Print the future
Page 68

From Giant Victoria Water Lily to an Aircraft Spoiler
Page 69
© AIRBUS Operations
S.A.S. All rights
GmbH.reserved.
All rights
Confidential
reserved. and proprietary
Confidential anddocument.
proprietary document.
First Outcome´s
Bionic Spoiler Demonstrator
Bionic Spoiler
Project
Bremen
Oliver Seack
2m ALM Powderbed machine South Africa
Page 70

Airbus Emerging Technologies & Concepts ALM Overview October 2016
Future Design & Production in Aviation – Bionic Partition
Page 71

Airbus Emerging Technologies & Concepts ALM Overview October 2016
Bionic AC Structures... ?
TOPOLOGY OPTIMISATION AIRBUS

VISION 2050 ENABLER
Seite 72
ETCG Awards, Pess Review, Presentations & Events October 2016
Hamburg CCH, October 11.th 2016, Airbus on stage:

Airbus Bionic Partition won the Component Award category AM
Page 73

ALM ProtoNet Partners

And finalists Deutscher Zukunftspreis:
74

© Airbus S.A.S. All rights reserved. Confidential and proprietary document. This document and all information contained herein is the sole property of AIRBUS. No intellectual property rights are granted by the delivery of this document or the disclosure of
its content. This document shall not be reproduced or disclosed to a third party without the express written consent of AIRBUS S.A.S. This document and its content shall not be used for any purpose other than that for which it is supplied. The statements
made herein do not constitute an offer. They are based on the mentioned assumptions and are expressed in good faith. Where the supporting grounds for these statements are not shown, AIRBUS S.A.S. will be pleased to explain the basis thereof.
AIRBUS, its logo, A300, A310, A318, A319, A320, A321, A330, A340, A350, A380, A400M are registered trademarks.
Airbus 3D Printing Video on YouTube

Fokus 28/16 WIRTSCHAFT & GELD
http://www.youtube.com/watch?v=Cy3V3KR1LW
Fliegen wie gedruckt
http://www.focus-magazin.de/
3D Printing Revolution:
http://www.harvardbusinessmanager.de/heft /
Thanks for your Attention!

I like to extend my network on ALM!
peter.sander@airbus.com
Download the new Airbus FAST Magazine with 3D Printing:

http://www.airbus.com/support/publications/?eID=maglisting_push&tx_maglistin Nominiert für den Deutschen Zukunftspreis: „Eine Fertigungsrevolution hebt ab“
g_pi1%5BdocID%5D=42444 http://www.deutscher-zukunftspreis.de/de/nominierteDie Welt: Das sind die besten deutschen
Erfindungen 2015
Page 75

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Airbus Emerging Technologies & Concepts ALM Overview November 2016

Emerging Technologies & Concepts

Emerging Technologies & Concepts

35 Years Aircraft Industry

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

On the way to Additive Manufacturing

1 – Emerging Technologies & Concepts

2 - 3D Printing / ALM – an Overview

3 - 3D Printing Platform Airbus

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

What is important within innovation ?

Innovation is the creation of better or more effective

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Customer Driven Innovation > BAG2GO > RIMOWA Electronic Tag

Discover the ease of flying

Customer Driven Innovation > BAG2GO > RIMOWA Electronic Tag

How to find the Ideas and disruptive idea owners?

 Speed and individual help for disruptive idea´s and - owners

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

3D Printing Challenge on Idea-Space to find new ALM Ideas

192 3D Printing Ideas collected in 5CW

GB / F / G / ES/ USA  2014

and awarded September 05.th

(Sponsor G. Butschek / Y. Barbaux)

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

1 – Emerging Technologies & Concepts

- Customer driven Innovations

- Space Technologies for Airbus Aircrafts ?

- 3D Printing & Bionic Design

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Terry Wohlers Report 2016

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

10 printed houses in 1 day?

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Target Dubai: 2030  25% houses=printed

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

ALM Airbus Group

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

On the way to Additve Layer Manufacturing:

2 - 3D Printing / ALM – an Overview

3 - 3D Printing Platform Airbus

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

3D Printing “ALM”: Technologies

Airbus Emerging Technologies &

Terry Wohlers Report 2016

Basis: 842 ind. Printer systems

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

© AIRBUS S.A.S. All rights reserved. Confidential and proprietary document.

Airbus ALM/3D Printing