Peter Zimm - MRO WORKSHOP - SPOTLIGHT: Additive manufacturing (3D printing) is expected to have a profound impact on global supply chains, including in the aviation industry. What does 3D printing mean for the future of manufacturers and MROs?
Peter Zimm - MRO WORKSHOP - SPOTLIGHT: Additive manufacturing (3D printing) is expected to have a profound impact on global supply chains, including in the aviation industry. What does 3D printing mean for the future of manufacturers and MROs?
Similaire à Peter Zimm - MRO WORKSHOP - SPOTLIGHT: Additive manufacturing (3D printing) is expected to have a profound impact on global supply chains, including in the aviation industry. What does 3D printing mean for the future of manufacturers and MROs?
Sustainability approach by design optimization for advanced layer manufacturingAlberto Garcia Romera
Similaire à Peter Zimm - MRO WORKSHOP - SPOTLIGHT: Additive manufacturing (3D printing) is expected to have a profound impact on global supply chains, including in the aviation industry. What does 3D printing mean for the future of manufacturers and MROs? (20)
Peter Zimm - MRO WORKSHOP - SPOTLIGHT: Additive manufacturing (3D printing) is expected to have a profound impact on global supply chains, including in the aviation industry. What does 3D printing mean for the future of manufacturers and MROs?
1. Additive Manufacturing for MRO
Rio de Janiero, Brazil
30 March
2017
Peter C. Zimm
Principal ICF
peter.zimm@icf.com
2. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Additive manufacturing (AM) “builds up” parts with material deposition,
rather than removing material through machining
ADDITIVE MANUFACTURING FOR MRO
TRADITIONAL MACHINING – “SUBTRACTIVE MANUFACTURING” ADDITIVE MANUFACTURING – “3D PRINTING”
Source: Simtech Simulations, MakerBot
3/30/2017 2
Large percentage of material wasted Complex structures impossible with subtractive
manufacturing techniques
3. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Additive machines are distinguished by the combination of material
feedstock and heat source
3/30/2017 3
ADDITIVE MANUFACTURING FOR MRO
Source: ICF
Power / Heat Source
Laser Electron Beam Plasma Arc
MaterialFeedstockType
WireFeed
Blown
Powder
Powder
Bed
ADDITIVE MANUFACTURING TECHNOLOGIES
4. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Two main types of processes are used for aerospace additive
manufacturing
3/30/2017 4
ADDITIVE MANUFACTURING FOR MRO
Source: Loughborough University, InssTek, Carbon3D, GE
Powder Bed Processes Direct Metal Deposition (DMD)
Material deposited before processing Material deposited during processing
Materials include Aluminium, Titanium alloys, Cobalt Chrome,
Stainless Steel, Silver, Gold as well as various plastics
Main metals are Cobalt Chrome and Titanium
Great surface finish and precision
Primarily for low-volume parts
Relatively high material deposition rates – better for serial
production
May require more post-processing
Size limited by processing chamber Size only limited by range of motion of deposition head
5. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Additive manufacturing offers many benefits to manufacturers
Drivers of
AM
Adoption
Lower Buy-To-
Fly Ratio
Lightweight
Designs
Part
Consolidation
Shorter Lead
Times
Small Lot
Sizes
Rapid /
Frequent
Prototyping
Enables More
Complex Part
Designs
3/30/2017 5
ADDITIVE MANUFACTURING FOR MRO
Source: ICF
6. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Assemblies and
complex parts
are prime
candidates for
AM processes
Whole Parts (Direct)
AM is well suited
to low volume,
high lead time
items such as
tooling, molds,
and fixtures
Whole Parts (Indirect)
Protrusions,
bosses, and
flanges could be
added to
simplified forged
rings
Add Features
Additive manufacturing can be used to make whole parts (whether direct or
indirect) as well as add features to existing parts
3/30/2017 6
ADDITIVE MANUFACTURING FOR MRO
USES OF ADDITIVE MANUFACTURING
Source: GE, EOS
7. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
CFM LEAP
Fuel
Nozzles
787
Production
Ducts
Housing &
Casing
Features
Liebherr
Prototype
Valve
Manifold
Additively
Repaired
Blade
P&W GTF
Compressor
Stators
Turbomecha
Fuel Injection
Nozzles
While early additive production achievements had been on small complex
parts (e.g. aero engine components) …
3/30/2017 7
ADDITIVE MANUFACTURING FOR MRO
QCOMPLETE PARTS QASSEMBLIES QFEATURES QREPAIRS
Source: ICF SH&E analysis, Boeing, Airbus, GE Aviation, DM3D, EU Project Merlin (Rolls-Royce)
8. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
… current technologies also allow the additive manufacture of large parts
3/30/2017 8
ADDITIVE MANUFACTURING FOR MRO
Trent XWB Front
Bearing Housing
1.5m in diameter
Largest ever civil aero
engine component
Constructed from 48
additively manufactured
vane components
Genx, GE9X LPT
Blades
Constructed by Avio Aero
(GE subsidiary)
Made from TiAl using EBM
Production rate nearly
matches that of casting
Norsk Titanium
Preform
Wire and plasma arc DMD
technology used
No necessary post
processing i.e. heat
treatment
In the process of becoming
aerospace qualified
9. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Additive manufacturing is making deeper inroads in engine production
3/30/2017 9
Siemens have recently completed full load engine tests
for their additively manufactured turbine blades
The blades were run at 13,000 rpm and reached
temperatures over 1,250°C
The blades incorporated redesigned improved cooling
features that help to increase the efficiency of the blade
ADDITIVE MANUFACTURING FOR MRO
Source: GE Reports, Siemens
GE are planning to build the world’s first turboprop
engine that utilizes additively manufactured components
for the Cessna Denali
Designers consolidated 845 parts into 11 3D printed
pieces, which will reduce production times
Other claims include a fuel burn reduction of 20% and a
10% increase in power as well as a reduction in the
weight of the engine
10. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
The advent and adoption of additive manufacturing for aerospace
production has been well publicized …
3/30/2017 10
ADDITIVE MANUFACTURING FOR MRO
Source: Norsk Titanium, GE, Airbus, ICF
Thousands of polymer additive parts have been flying for years – it is metal additive that is emerging
11. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
… but a number of additive manufacturing benefits are also applicable to
parts found in mature and sunset aircraft
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ADDITIVE MANUFACTURING FOR MRO
APPLICABILITY OF ADDITIVE MANUFACTURING BY LIFE CYCLE STAGE
Source: ICF
AM Benefit Design Growth Mature Sunset
Lightweight Designs X
Part Consolidation X
Rapid Prototyping X ?
Complex Designs X
Reduced Material Cost X ?
Reduced Labor Cost X ?
Reduced Tooling Cost X X X
Short Leadtimes X X X X
Small Lot Sizes X X X
12. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
The EU’s RepAIR Program aims to integrate additive manufacturing into
aircraft MRO
3/30/2017 12
ADDITIVE MANUFACTURING FOR MRO
Source: EU Seventh Framework Program / University of Paderborn: “RepAIR – Future Repair and Maintenance for Aerospace Industry”
University of
Paderborn (UPB)
13. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
The study found additive manufacturing could provide numerous benefits
to MRO
Reduce repair and overhaul costs of complex spare parts by 30% and the turnaround time by 20%
Increase the automation level for spare parts production processes by 20%
Reduce scrap and toxic chemicals in the repair process by 80% and part weight by min 20%
Increase the technology readiness level (TRL) of innovative repair processes to level 4 focusing on the AM
technology
Develop processes to decrease certification effort for additive manufactured aeronautics and air transport spare
parts in terms of cost and time based on an integrated quality control and process data monitoring
Reduction of inspection time by 30% by integrating continuous health management and usage-based prognostics
Strengthen the business model of European MRO service provider in the world by integrating a complete
production and supply chain for complex spare parts
RepAIR 2020 Objectives
Shorter lead times
Optimized fabrication in terms of material costs
Lightweight design of AM parts reduces part and lifecycle costs of airplanes
RepAIR Additive for MRO Findings
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ADDITIVE MANUFACTURING FOR MRO
Source: EU Seventh Framework Program / University of Paderborn: “RepAIR – Future Repair and Maintenance for Aerospace Industry”
Lower overall part cost
Optimized supply chain
14. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Qualified as AM
parts
Not originally
qualified as an
AM part
Whole Parts (Direct)
AM can
significantly
reduce time and
cost to produce
parts for sunset
programs
Whole Parts (Indirect)
Blade tip
welding and
other traditional
additive repairs
could be
performed with
greater precision
Repair
Additive manufacturing can be used to make MRO whole parts (direct or
indirect) and add features (i.e., additive repairs)
3/30/2017 14
ADDITIVE MANUFACTURING FOR MRO
MRO USES OF ADDITIVE MANUFACTURING
Source: GE, EOS
15. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Example: Replacement Parts
3/30/2017 15
ADDITIVE MANUFACTURING FOR MRO
Source: ATR, MRO Network, Stratasys
Interior cabin parts for sunset aircraft
Often, old molds are unusable or a part is no longer available
Previously a new mold would have to be made, costing
thousands of dollars.
Minimum orders are usually in the hundreds in order to make
the part viable economically
It is now possible to manufacture a single component,
reducing not only production costs, but also the warehouse
costs of storing 10+ years of excess parts ordered
Traditional Production Additive Manufacturing
Molds and techniques outdated Up to date technologies
Minimum order of 200 pieces Possible to manufacture a single part with no economic drawback
Long lead times
Manufactured in house: rapid iterative prototyping and final
component production can take weeks not months
16. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Example: Prototyping and Tooling
3/30/2017 16
ADDITIVE MANUFACTURING FOR MRO
Source: MRO Weekly
Traditional Techniques New AM Techniques
Long lead times for each prototype Rapid prototyping can produce parts from cad designs in hours not
days
Machining and material costs drive up price of prototype Relatively cheap plastics and machine running costs mean
inexpensive prototypes are possible
Air France Industries is already using additive manufacturing
for tooling and prototype design purposes
Accurate prototypes can be used to test the fit of parts and
the speed of production combined with relatively low cost
promotes iterative design, with prototypes being refined and
re-printed methodically
Final parts are then manufactured using conventional
techniques
This process has been used to prototype a CF6 turbine rear
frame repair part as well as Boeing 787 seat track covers
17. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Example: MRO Tooling – Safety Collar / Flap Immobilizer
3/30/2017 17
ADDITIVE MANUFACTURING FOR MRO
Source: Satair, MRO Newtork
More freedom to manufacture tools additively as there are
fewer certifications needed
Previously machined from a titanium block
Topology optimization was used to determine where strength
is needed, and where material can be removed
New design is half the weight, saving material and
promoting ease of use
Satair have selected 60 other tools to be manufactured
additively
Traditional Production Additive Manufacturing
Heavy and bulky Light weight (50%) and slim design
Unnecessary material and wasted material during manufacture Topologically optimized to use minimum necessary material
Other disadvantages: Difficult to machine, sharp edges
Other benefits: Rounded corners and edges, increased ease of
use due to weight savings, looks good!
18. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Example: Tailored Part Repair
3/30/2017 18
ADDITIVE MANUFACTURING FOR MRO
Source: Satair
New research being done into customizable tailored part
repair. Applications would suit damaged turbine blades.
3D scans of damaged parts combined with files containing
their original geometries allows the computer to calculate the
exact action needed to restore the part
Direct metal deposition ‘fills in the gaps’ depositing metal
precisely where needed in order to match the physical part to
its original geometry
Traditional Techniques New AM Techniques
Needs a person to assess the damage and decide on action Computer can assess damage and plan repairs
Requires a skilled human to build weld by hand to restore part CNC machinery executes the repair to exact specifications
19. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Example: Wing Repair
3/30/2017 19
ADDITIVE MANUFACTURING FOR MRO
Source: ATR
ATR additively manufactured a patch to repair the leading
edge of a wing
The patch was constructed from titanium for its strength and
weight advantages
The patch was able to be manufactured to specification and
specific to the individual repair job, providing the support only
where required
The part used less material and was subject to shorter lead
times in comparison to a machined alternative
Traditional Techniques New AM Techniques
Long lead times Shortened lead times
Generic solutions that require modification by hand Parts created specifically for the task, are completely compatible
with no modification required
20. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Cold Spray (CS) repair process approved for military applications
3/30/2017 20
Cold Spraying involves accelerating metal powder
to supersonic speeds
The particles are ejected from a nozzle at a
substrate
Upon impact with the substrate, the deformation of
the particles generates localised heat which welds
them to the surface
Layers of cold spray can be applied in order to
build or rebuild a coating on the surface of a
component; like 3D painting
It can also be used to regenerate a component that
has become worn down over time
ADDITIVE MANUFACTURING FOR MRO
Source: GE
21. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
RUAG has developed and obtained approvals for 40 cold spray repairs on
both fixed wing aircraft and helicopters
3/30/2017 21
ADDITIVE MANUFACTURING FOR MRO
Source: RUAG
RUAG is applying DMD technologies to coat and clad parts as well as create
3D printed near net parts with cold spray
22. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Early application of additive manufacturing began to improve aftermarket
support to operators
3/30/2017 22
ADDITIVE MANUFACTURING FOR MRO
Source: Daily Mail, Airbus
RAF Tornado
BAE producing protective covers
for cockpit radios and guards for
power take-off shafts to sustain
RAF Tornados via AM
Parts first flew in December 2013
These AM parts could cut RAF’s
maintenance costs by $1.9M over
four years
Air Transat A310
In February 2014 the first AM
component – a small plastic crew
seat panel – flew on an Airbus
customer jetliner
The aircraft was an A310 operators
by Air Transat
Like most aircraft OEMs, Airbus is
working towards “on demand” spare
parts
23. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
OEMs and MROs are using additive manufacturing to build spare parts and
tools for mature and sunset platforms
3/30/2017 23
ADDITIVE MANUFACTURING FOR MRO
Source: Aviation Week, ICF Research
Struts, guards and
covers
UK Royal Air Force
Tornado GR4
BAE Systems
Support struts for air
intake doors
Protective guards for
power take-off shafts
Cockpit radio covers
Interior Parts
Various Aging
Aircraft
ST Aero
3D printing castings
for PMA interior parts
Decreases time to
develop molds
Breather Pipes
Regional Jets
BAE Systems
40% cost savings
compared to injection
molding
Recently received
EASA approval
Tooling
Various Aging
Aircraft
Advanced Composite
Structures
Additively
manufacturing tools
for the repair of
composite structures
Engine
Components
LEAP Engines
CFM
19 AM Fuel Nozzles
in each engine
Combines previously
18 parts into a single
piece
25% Lighter than
previous fuel nozzle
24. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
There are several critical barriers to adoption of additive manufacturing in
aerospace
3/30/2017 24
ADDITIVE MANUFACTURING FOR MRO
Source: ICF analysis
Additive
Manufacturing
Barriers
Engineering
Mind-set
Cost
Machine
Throughput
Materials
Development
Quality and
Repeatability
Qualification
and
CertificationCertification may be the
most critical barrier
25. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
For operators, additive manufacturing holds the promise of improved
aftermarket support
3/30/2017 25
ADDITIVE MANUFACTURING FOR MRO
Source: ICF
Operators of mature and sunset aircraft are often frustrated by long
lead times and excessive prices for OEM service parts
AM will also see widespread application for parts repairs; examples
include cold spray and turbine blade repairs
Additive manufacturing offers the potential of an aftermarket
paradigm shift for certain parts, collapsing lead times to a fraction of
current levels
As certification issues are addressed…AM may also be adopted by
PMA parts suppliers and MRO firms, offering greater choice to
operators
27. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Aerospace & MRO Advisory Support
27
AEROSPACE & MRO
ICF guides manufacturers, airlines, independent MROs, suppliers, and the financial
community through every step of the aerospace and MRO supply chain to realize
value and deliver strategies that drive growth. We understand and focus on the key
aspects of the industry, and have the proprietary tools necessary for successful
operations. Below, we briefly describe our core aerospace & MRO services and
proprietary supporting products.
ICF focuses on
key aspects of the
industry that drive
value in both
revenue growth
and cost control.
Strategy Development
Leveraging years of aerospace and MRO
advisory experience as well as proprietary
market intelligence, ICF delivers data-driven,
objective insight to underpin
sustainable strategies.
Transaction Support
For clients’ investment decisions, ICF
combines global thought leadership in
aerospace and MRO supply chain with
accurate market intelligence, operations
expertise, and unparalleled industry contacts.
Operations and Supply Chain
ICF’s proven tools and methodologies offer
improved performance and cost reduction
across manufacturing, operations, and all
phases of make-buy supply chain planning
and execution.
MRO Business Improvement
For airlines, OEMs, and independent MROs,
ICF has deep experience in comprehensive
operational and financial diagnostics based on
extensive proprietary benchmarks, followed by
results-oriented improvement programs.
AEROSPACE & MRO PRODUCTS
ICF’s suite of proprietary
aerospace & MRO tools, models,
and databases helps stakeholders
navigate key business challenges
to their advantage.
Fleet &
MRO Forecasts
Aircraft Manufacturing
Database
MRO Best Practices
and Benchmarks
Proprietary, independent forecasts for
commercial and business aviation,
industrial gas turbine, and
military markets.
Production value breakdown by
component category and raw
material content across the
aerospace supply chain.
Comprehensive, proprietary databases
on processes, costs, and organization.
3/30/2017
28. ICF proprietary and confidential. Do not copy, distribute, or disclose.ICF proprietary and confidential. Do not copy, distribute, or disclose.
Operations & Supply Chain Advisory Support
28
OPERATIONS & SUPPLY CHAIN
ICF offers an alternative cost reduction and performance improvement approach for
aerospace manufacturers. ICF’s small, experienced teams employ a focused method
to quickly target the greatest opportunities from a relevant set of facility data while
using minimal client resources. Once implemented, ICF’s recommendations maximize
improvement and drive meaningful, long-term, and sustainable gains to the company’s
bottom line.
ICF focuses on
key aspects of the
industry that drive
value in both
revenue growth
and cost control.
OPERATIONS & SUPPLY CHAIN
PRODUCTS
ICF’s suite of proprietary
operations & supply chain tools,
models, and databases help
stakeholders realize cost reductions
and performance improvements.
6 Step Diagnostic
Framework
Cost & Performance
Benchmarks
Aircraft Manufacturing
Database
A proven process that minimizes
disruption to you and your team while
maximizing actionable results from a
rapid assessment of operations and
supply chain activities
Proprietary benchmarks of multiple
cost categories and operations
metrics by part families, operation
types, and materials .
Production value breakdown by
component category and raw
material content across the
aerospace supply chain
• Supply chain maturity and supply chain
risks diagnostic
• Standardization of end-to-end supply
make/buy activities
• Evaluation of supplier performance &
improvement actions
Ops & Supply Chain Excellence
• Identification & management of cost
side drivers of the
income statement including overhead /
wrap rate
• Manufacturing cost structure and
purchase spend analytics
• Managing global transitions including
to low cost countries
Cost Reduction
• S&OP maturity diagnostics including
ramp up readiness
• Efficient execution of product
development through standardization
• New technology insertion including
additive manufacturing diagnostics
New Product Introduction
• Complete operations due diligence
including manufacturing ops,
procurement, engineering and other
factory support with clear identification
of margin risks and mitigation
• Quantify and implement cost synergies
• Quantify and implement enhanced
leverage for purchases
OSC Excellence
3/30/2017