Making it happen

Making it happen
Making it happen

Roc-Aire's general manager, Jason Collins explains how, through the use of Verisurf's measurement software and 3D printing, part realisation has helped speed up its MRO applications.
Founded in 1958, innovation has been at the heart of California-based Roc-Aire's culture from the beginning, starting with its involvement in the space race and eventual development of supersonic aircraft like the Lockheed SR-71. One of the company's early milestones was developing a process for machining titanium. Today, as in the early years, Roc-Aire stands out as a ‘can do' contract manufacturer known for solving problems and overcoming obstacles.

“Some people make excuses; we make parts,” begins company general manager, Jason Collins. “It's not just about cost with our customers, it's about value. We strategise with them on engineering, materials and processes to make sure the parts we are producing are as good as, if not better than the originals.”

Roc-Aire combines this innovative thinking with Verisurf Measurement Software and 3D printing/additive rapid manufacturing to increase customer value and shorten development time. The process often improves form, fit and function of failed or worn legacy aircraft components during maintenance, repair and overhaul (MRO).

Going forward in reverse

Legacy parts are reverse engineered using Verisurf Reverse software and are then 3D printed to high precision prototypes to evaluate form, fit and mechanical function. Using Verisurf software the finished prototype is then inspected and directly compared to the original STL mesh model, maintaining a digital workflow throughout the entire process. Whether for new parts or MRO applications, reverse engineering and 3D printing can improve engineering and build processes and reduce development time.

“The benefits of using these methods are tangible,” states Collins. “Reverse engineering and 3D printing has proven to be an essential part of our development workflow. We use the high precision, demonstrable prototypes for much more than just form and fit. Quite often we rely on the prototypes to support customer engineering discussions. Customers appreciate the value-add and the interactivity of a prototype leads to more productive meetings with a bias for action. Bottom line, projects move forward more quickly with better end results.”

When the parts for an older aircraft need to be replaced there are often no spares, no CAD data, and the original tooling is no longer available. After years of use the original design spec for parts such as duct work, for example, may no longer fit as designed. In some cases, an originally designed part may have a design flaw that has been amended. In each case reverse engineering and product realisation provide practical ways for engineers to identify problems and apply recommended solutions. A part that would typically take eight to sixteen weeks to create can now be produced as a high-precision model in just a couple of days. The customer is then able to do a fit check using the model and approve production with confidence.

Verisurf Software has the ability to inspect high tolerance prototypes directly to the STL model used by 3D printers, or to virtually any other 3D CAD format. This provides workflow and customer quality reporting flexibility. A presented prototype and inspection report, all tied to the STL model, can be established as the approved nominal design. Final inspection and reporting of the finish part can be completed using the same STL or the approved 3D CAD model. In both cases, the integrity of the digital workflow is maintained.

Meeting the challenge

Roc-Aire often faces challenges with reverse engineering, improving design and manufacturing replacement components for legacy equipment, whether it be landing gear, wing struts, or ventilation duct work. In order to speed the development time and depending on the size of the finished part, Roc-Aire will create either a full size or scale model. During design review meetings engineers are able to handle the 3D model and all of its components. This helps speed up the approval process and demonstrates real value to the customer. The end result is usually a modified part completed in weeks instead of months.

The process is generally straightforward. First the original part is disassembled and each component carefully reverse engineered using Verisurf Software. The data is typically captured using a Faro portable CMM with a contact probe.
“Contact probing provides greater measurement accuracy over non-contact scanning. Non-contact scanning is typically better for checking large surface areas for deviations, or capturing/inspecting complex surface profiles,” says Collins.
Verisurf Reverse Software converts the captured point cloud data into STL mesh models suitable for 3D printing and again into 3D solid models for export to popular CAD formats. Design modifications are then made and final prototype components output to a Stratasys Dimension 1200es 3Dprinter.

Following design review and approval, the 3D prototype can be used as a representative model for subcontractors involved in the manufacturing process: machining, welding, coating and final assembly.

“No number of drawings or computer models can replace the value of a 3D part to fully understand design intent, avoid costly mistakes and speed production,” concludes Collins.

Verisurf Software is used throughout the design process from reverse engineering to prototype validation and final verification. A first article AS9102 inspection report is generated for each completed part.

www.verisurf.com

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