Achtung:

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Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13. Show image information
Industry partners of the DMRC. Show image information
Industry partners of the DMRC. Show image information
Quality control during a Laser Sinter (LS) build job by a researcher of the DMRC. Show image information
Fused Deposition Modeling (FDM) process during the manufacture of an Ultem 9085 part. Show image information
Additive manufactured reaction wheel bracket for telecomunication satellites. Show image information
Employees of the DMRC working with the "freeformer" from Arburg. Show image information
Tactile measurement of a SLM part with a Coordinatemeasuring machine (CMM). Show image information

Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13.

Industry partners of the DMRC.

Industry partners of the DMRC.

Quality control during a Laser Sinter (LS) build job by a researcher of the DMRC.

Fused Deposition Modeling (FDM) process during the manufacture of an Ultem 9085 part.

Additive manufactured reaction wheel bracket for telecomunication satellites.

Employees of the DMRC working with the "freeformer" from Arburg.

Tactile measurement of a SLM part with a Coordinatemeasuring machine (CMM).

RepAIR – Future Repair and Maintenance for Aerospace Parts

The goal of this research project with twelve partners from all over Europe and from the US is the onsite maintenance and repair of aircraft by integrated direct digital manufacturing of spare parts. Cost efficient and lightweight but robust reliable parts are obligatory for aircrafts. Additive Manufacturing allows completely new approaches: The main objective of RepAIR is to shift the ‘make-or-buy’ decision towards the ‘make’ decision by cost reduction in the remake and rework of spare parts and therefore to improve cost efficiency for maintenance repair in aeronautics and air transport.

The project aims to reduce the Maintenance, Repair and Overhaul (MRO) costs with the help of the Additive Manufacturing (AM) technology as its crucial advantage is the flexible availableness allowing on-time maintenance without having the need of sophisticated supply chains. The AM operations require a higher qualification and promote the preservation and expansion of highly qualified workplaces in Europe.

RepAIR objectives showing the overall project idea and its components

Moreover, the storage costs will be significantly reduced and less capital is locked up. Additionally, hardly any energy-intensive produced raw material will be wasted or destroyed, but will be used optimally. New business models will become sustainable. When applied in design of new parts, the technology allows significant weight savings. These weight savings will result in less fuel consumption, therefore in a more sustainable way of flying and in a reduced carbon footprint.

European maintenance service providers have to deal with an enormous financial pressure. Competitive carriers focus intensely on low costs of repair services and materials while retaining consistent parts and service quality. The maintenance of complex components such as engines still takes place at nearly 100% in Europe. But for European MRO providers the danger of further displacement still endures.

To face this danger one has to keep and expand the advance through mastery of knowledge and technological lead. Based on the effort of the producers to reduce quantity and variety of components, multiple functions will inevitably be merged in complex components, whose maintenance could be taken over by technological leading MRO providers. For cost optimized work, one has to decide specifically if each component has to be replaced or could be reworked or recreated. If the costs for the production and the overhaul of complex components were considerably reduced, the decision would automatically be postponed from ‘buy’ to ‘make’.

A particular prospective benefit is promised by the AM technology. It offers a considerably lower buy-to-fly ratio of material, an omission of harmful chemicals (e.g. cutting oil) and constant manufacturing efforts at an increasing complexity (single piece assembly). Further improvements of the technology concerning the processing time, accuracy and costs are foreseeable. However, a holistic integration in the MRO processes is not yet researched.

Further project information
Project statusIn progress
Project duration 36 months
FundingFunded by the 7th framework programme of the EU
Project manager Prof. Dr.-Ing. Rainer Koch, University of Paderborn – C.I.K.
 
Project coordinatorDr.-Ing. Jens Pottebaum, University of Paderborn
Scientific staff Gereon Deppe, Christian Lindemann, Ulrich Jahnke, Thomas Reiher, Marco Plaß (C.I.K.)
Involved chairs Computeranwendung und Integration in Konstruktion und Planung (C.I.K.), University of Paderborn
 
Contact

Prof. Dr. Rainer Koch

Computeranwendung und Integration in Konstruktion und Planung

Rainer Koch
Phone:
+49 5251 60-2258
Fax:
+49 5251 60-3482
Office:
P1.3.19

M. Sc. Gereon Deppe

DMRC

Decision Support for Additive Manufacturing in terms of Quality, Costs and Time

Gereon Deppe
Phone:
+49 5251 60-2263
Office:
P1.3.24

Dipl.-Ing. Ulrich Jahnke

DMRC

Lifecycle Costs, Intellectual Property Rights and Prevention of Product Piracy

Ulrich Jahnke
Phone:
+49 5251 60-2290
Office:
P1.2.10.8
Web:

M. Sc. Thomas Reiher

DMRC

Part design optimization

Thomas Reiher
Phone:
+49 5251 60-2263
Office:
P1.3.24
Web:

Marco Plaß

Computeranwendung und Integration in Konstruktion und Planung

Marco Plaß
Phone:
+49 5251 60-2227
Fax:
+49 5251 60-3206
Office:
P1.3.27
Web:

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