... discovering what the members of the community are doing and their outcomes...
THE CHALLENGE
Development of additive layer manufacturing (ALM) has not only been limited to small and intricate components. Rolls-Royce have pioneered the development of larger significant parts and associated technologies for structural engine components. The front bearing housing is the largest aero engine structure to fly, incorporating ALM components, in the world to-date (Nov 2015).
MTC'S SOLUTION
Working in conjunction with Rolls-Royce and Arcam, MTC developed processes from powder inspection and characterisation through component manufacture to post process nondestructive testing of the ALM components
Embedded integrated project team with the machine manufacturer, the MTC and Rolls-Royce working together
Secure and confidential development location
Facilitated fast iteration of designs
Provided access to world-leading expertise in powder characterisation for additive manufacturing
THE OUTCOME
Hundreds of aerospace quality components manufactured under full Rolls-Royce control
Tens of thousands of equipment run hours with extensive data capture
Electron beam additive manufactured components incorporated into ground and flying test bed XWB-97 engines
BENEFITS TO THE CLIENT
30% improvement in lead time for first development parts to stores
Fast iteration and design change implementation throughout project
Product and process knowledge captured for us in future Rolls-Royce programmes
Transferable capability and knowledge obtained as a result
Appreciation of economic business case drivers
Continuous improvements made to technology platform in conjunction with integrated project team
Proof of Concept related to Process development and optimization in the context of Aerospace (Aeronautics)
