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A key component to the success of this project is partner collaboration. ¸é¨¦±è±ô¾±³¦¡¯´¡¾±°ù enlisted the support of Expleo (formerly Assystem Technologies) and PRISMADD to produce and deliver unique 3D printed metal parts to equip the aircraft ¨C specifically for the engine¡¯s cooling system, an assembly of five manifold blocks of pipes and reservoirs. Expleo is an engineering group who assists its clients in their digital transformation whereas PRISMADD is dedicated to the realization of its client¡¯s parts ¨C simple to complex, often through 3D printing.

Initially, the supporting partners redesigned and manufactured the 3D printed replicas for the engine¡¯s cooling system without the benefit of simulation. This led to unanticipated distortion, porosity and gaps between layers (particularly due to thin walls) ¨C not to mention hours of time lost and materials wasted. An estimated 20K€ in materials and a one month delay resulted from every two defective prototypes produced. To meet their deadline for a fully functioning plane, they realized that simulation would help them identify the best design for their parts in the shortest timeframe possible. For this, Expleo turned to the simulation software they apply to their own 3D printing needs, ESI Additive Manufacturing simulation software.

With the confidence of highly accurate simulation results, established on more than 10 years of Additive Manufacturing project collaboration experience using ESI Services, the project team quickly identified thesource of problems and modified by:

• increasing body wall thickness in specific areas to limit distortion and porosity of thin walls in the 3D printing process
• repositioning an anti-sloshing grid to avoid the edge distortion and enable a seamless, ¡°watertight¡± assembly
• adjusting the surrounding support strategy to significantly reduce the distortion-induced porosity.

Through effective simulation of the Additive Manufacturing process, the team was able to evaluate multiple iterations and arrive at an improved design. ESI Additive Manufacturing simulation enabled Expleo and PRISMADD to develop and produce all five components correctly, on the first try, in the shortest timeframe, and for the least amount of money ¨C which certainly pleased ¸é¨¦±è±ô¾±³¦¡¯´¡¾±°ù.

Created in 2011 by a core of enthusiasts of Aeronautics, the R¨¦pilc'Air association wants to revive the spirit of our pioneers and promote aerospace. Today, it has about eighty members of all ages and all backgrounds.

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