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3d-printing-in aerospace-bracket

Wipro 3d offers 3d Printing in Aerospace Industry to meet the growing demand for light weight components achieving drastic reduction in lead-time to realize components, reimagined and delivered components for a leading Aerospace OEM

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3d-printing-in aerospace-bracket

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  1. AEROSPACE Component Bracket Material AlSi10Mg The Aerospace industry has been at the forefront of adapting Metal Additive Manufacturing (AM) and some of the most evolved applications of metal AM can be found in the aerospace sector. Leading OEMs, tier 1 suppliers, and key ecosystem players are in the phase of developing mature capabilities in metal AM. T Typical value contribution from Metal Additive Manufacturing comes in form of weight reduction, reduction in sub-assembled parts by creating monolithic designs, ability to realize complex designs and drastic reduction in lead time to realize components.

  2. ABOUT THE PROJECT The ‘Bracket’ was chosen as a low-risk structural element to reduce weight, to be later scaled to a variety of parts. In order to reduce deflection and weight of the ‘Bracket’, a sizeable amount of its mass had to be reduced. Wipro 3D, in collaboration with a partner, determined the stress plot based on boundary conditions and lo loading conditions, which was then used to reduce mass not integral to the part’s function. An innovative bio-design composed of features with evolving diameters was arrived at. The Additively Designed Bracket was then manufactured using Wipro 3D’s proprietary Additive Thinking Framework and was realized in h hours. The ‘Bracket’ is currently under meticulous testing for Airworthiness Qualification.

  3. AM COMPETENCIES USED The initial design contained a lot of mass in the bracket. With the stress plot as a foundation, Additive Design was used to eliminate mo more than 50% of the mass. POST PROCESSING ADDITIVE DESIGN & ENGINEERING A series of well-planned post processing activities were coordinated and executed to achieve the Bracket’s desired surface finish and me mechanical properties. BUILD TECHNOLOGY Due to its interwoven structure, the component was challenging to realize in AM. Wipro 3D used its proprietary Additive Thinking Framework to de design innovative supports and realize the ‘Bracket’.

  4. AM VALUE ADDITION Structural integrity was drastically improved as the deflection was reduced by 74%. Owing to Wipro 3D’s redesign 53% of weight was reduced. IMPROVED PERFORMANCE WEIGHT REDUCTION With the process package established, the customer now has the ability to make efficient design alterations to improve the functional pe performance, with very short “Redesign-to-realize” cycle time. DESIGN FREEDOM TIME-TO-REALIZE The complete redesign to realize lifecycle for the ‘Bracket’ was done in less than 2 weeks. About Wipro 3D Wipro 3D is an AS9100 Certified metal AM solutions and services provider, serving Aerospace, Space, Defense, Industrial, Heavy Engineering, Automotive, Energy, Nuclear & Healthcare sectors. Our solutions include AM Consulting, Additive Engineering & Design Offerings, Manufacturing Services, Research & Development based solutions right unto Design - Deployment and Operation of captive metal AM centers. Visit: http://wipro-3d.com to learn more

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