Achtung:

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Lattice structure tensile specimen manufactured with laser melting (LM) process out of the material H13. Show image information
Partner of the DMRC Show image information
Partner 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
Powder particles are used as raw material for laser-based additive manufacturing Show image information

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

Partner of the DMRC

Partner 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)

Powder particles are used as raw material for laser-based additive manufacturing

Aircraft bracket case study

Figure 1: Topology Optimization of the bracket

Objectives
The main purpose of this case study was to demonstrate the potential of Laser Melting for the development of brackets for the aircraft industry. Therefore, a given bracket should be redesigned, technical and economic benefits should be analyzed.

Procedure

For this case study a bracket was considered that mounts the luggage compartment damper to the aircraft structure. Its geometry was designed with topology-optimization methods. Under consideration of design rules from the Direct Manufacturing Design Rules project, the bracket was further designed in order to stick to manufacturing constrains and to minimize post-process operations. The bracket was manufactured and tested with several different loading conditions in order to prove its functionality.

Figure 2: Bracket design with internal structures

Achievements

Generally, the case study proofed that additive manufacturing can provide great advantages for the fabrication of brackets. In this particular case, the following achievements could be obtained:

  • Weight reduction of -46.2% (16.13 g) compared to the milling part (29.98 g)
  • Manufacturing cost increase of 39.47% (92.19 €) compared to the milling part (66.11 €)
  • Lifetime cost reduction of -39.50% (511.57 €) compared to the milling part (845.57 €)
Figure 3: Testing of the manufactured bracket
Figure 4: SLM-manufactured bracket

The Company H&H GmbH – partner of the DMRC since 2013 – offers all the development services required to transform an idea into a series product. Thereby, H&H develops and builds prototypes and then simulates, tests and produces the idea that has taken shape in series volumes.

Contact

Prof. Dr. Detmar Zimmer

DMRC

Additive Manufacturing: Design Rules, functionality, function integration

Detmar Zimmer
Phone:
+49 5251 60-2256
Fax:
+49 5251 60-3206
Office:
P1.3.17

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