Adapt and overcome

It goes without saying that the past year has been particularly difficult for the commercial aerospace industry, with significant implications experienced throughout the supply chain. The pandemic’s reach extends far beyond commercial aviation too, slowing or even cancelling projects in other parts of the sector.

This pause, however difficult, has given us time to reflect and ask ourselves some important questions. Is this really the best way? Why are we approaching it like this? What can we do to improve?

In comparison to other industries, aerospace technology is often perceived to move quite slowly. The frontier of research well and truly eclipses current products, while development cycles are often in excess of ten years. While some of this can be attributed to the extremely rigorous safety protocols and standards that have evolved across the industry, it is not the only explanation.

Often, the level of investment required to start a new aerospace project means that manufacturers wait for a step-change in technology. While there is room for iterative improvements, all-new products must deliver significant and meaningful benefit to their customers over existing solutions.

In the commercial aviation industry, this presently boils down to operational cost and meeting public and legislative pressure for cleaner transportation. In the space industry, it means substantially reducing the cost of launch. For defence projects, it is cost versus performance and operational outcomes. Given these challenges, can additive manufacturing (AM) deliver the step-change the industry needs?

While often dismissed as ‘rapid prototyping’ and prohibitively expensive, I can confidently say that additive manufacturing has already evolved into a highly capable serial production technology. Not only that, but AM brings a whole host of other powerful benefits, from unique part design to on-demand manufacturing.

For those looking to reduce the carbon footprint of manufacture, AM happens to be one of the most energy- and material-efficient means of production. Not only that, but the technology has progressed to the point where it can deliver significant cost savings if considered and designed for from the beginning of a project (and the part life cycle cost analysis).

In the quest for improved performance and efficiency, lightweighting is one of the industry’s most important trends. AM can create parts that no other process feasibly could, simultaneously cutting weight while improving performance. This is already being noticed by high-profile projects like the upcoming fifth-generation Tempest, which BAE intends to make out of 30% AM parts – up 29% from the Eurofighter.

It is not just performance though; additive manufacturing can also significantly reduce the number of required components. Take a look at General Electric’s Catalyst turboprop engine to realise that reducing 800 components down to just 12 delivers a vast range of benefits.

When it comes to maintenance, AM’s ability to produce spare parts on-demand without tooling is a capacity that looks to revolutionise the entire supply chain. It could drastically reduce operating costs and downtime, delivering significant savings over a product’s lifecycle.

While additive manufacturing is not the answer to every challenge, it is one of the most promising options as we embrace the fourth industrial revolution. At the DMC, our focus is on collaboration, digital connectivity and bringing together the best manufacturing capabilities, like our partnership with aerospace specialist engineering company, Produmax.

Using an engineering-led approach and unparalleled support, we are leveraging horizontal innovation to provide our customers with state-of-the-art additive, subtractive and net shape manufacturing – backed by finishing and inspection services.

Uncertainty may linger, but every day marks a step towards the aerospace industry’s inevitable recovery. At the DMC, we are eager and optimistic, with a number of high-profile aerospace projects already in the pipeline. While budgets may be strained, now is the perfect time to question established and conventional thinking. Is there a better way? What’s more, how can we improve performance and efficiency, reduce costs and work more sustainably?

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