The main aim of the DMRC work scope in the VERONIKA project is to enhance the understanding of AM for the aircraft cabin industry. AM implies high benefits for components of the aircraft cabin due to its high design freedom and potentially lower costs for small series. The applicability of the AM technologies fused deposition modelling, laser melting and laser sintering for components of the aircraft cabin shall be increased by consideration of several case study parts for different target aims and by development of process chain instructions for reproducible manufacturing.
The DMRC participates in two work packages of the collaborative project VERONIKA. In the first work package – Process Chain of Rapid Engineering – two different studies were worked out. The first study deals with the different AM processes and their processable materials. The second study is about part selection and design rules for parts generated by AM. Furthermore, material properties are determined and FE models are developed. A production instruction based on quality management will be prepared for the selected aircraft cabin components from WP2. Finally, a validation of the process chain shall be performed. In the second work package – Application of Additive Manufacturing – the project partners submitted several components of the aircraft cabin, which are parts for conventional manufacturing, and filled out a specification sheet template which was provided by the DMRC. Subsequently, several parts of the submitted cabin parts were selected by using a trade of methodology. Enabling factors for the selection are for instance highly complex parts, a high buy-to-fly ratio for conventional production, several contact points to surrounding parts or the possibility to integrate functions. The aim for the selected parts is then to perform a change into an AM compliant design and an optimization regarding material change, weight, part integration or function integration by e.g. topology optimization. Thereupon, process parameters shall be defined and demonstrators shall be produced. Further, the demonstrators shall be verified and squared with the specification analysis.