<p>THE CHALLENGE</p><p>Typical economy class seats today weigh around 12-13 kilograms. Achieving weight saving under strict sizing and loading regulations can be difficult using conventional manufacturing methods.</p><p>To achieve weight saving, Assystem were looking to develop expertise in design for Additive Manufacturing (AM), specifically through the use of Electron Beam Melting (EBM), to gain in-depth knowledge of AM possibilities.</p><p>MTC'S SOLUTION</p><p>In partnership with Assystem, the MTC helped with the redesign of the seat bracket, using AM topology optimisation software to form a lighter structure. </p><p>The full seat structure was manufactured in titanium using the EBM process, providing a solution via non-conventional manufacturing.</p><p>The MTC developed and optimised EBM parameters to minimise process defects and improved part integrity.</p><p>Post-processing of the AM part, including polishing to improve the surface finish was carried out, followed by an inspection using X-Ray Computed Tomography (XCT).</p><p>THE OUTCOME</p><p>A demonstration of how AM can be used to manufacture complex geometries</p><p>Weight savings by 30% through topology optimisation</p><p>The MTC developed process parameters to improve the integrity of AM parts</p><p>Validation of the part quality through Non-Destructive Testing (NDT) using XCT, providing Assystem with a greater understanding of detection of defects, and quality analysis for AM parts</p><p>BENEFITS TO THE CLIENT</p><p>Weight savings of 30% on seat structure, leading to reduction in costs for client</p><p>Increased knowledge of the AM process, including understanding the role, requirements and influence of topology optimisation and post-processing</p><p>Increased knowledge of design and validation of highly complex and efficient geometries for AM production, to support existing aerospace AM capability</p>
Authored by Tian-Long at June 28, 2022, 10:28 a.m.