Aircraft sustainability depends on new technology

Additive manufacturing now creates lighter parts for the aerospace industry. TRUMPF

Laser technology and additive manufacturing are key technologies for manufacturing sustainably operable aircraft. This was the message shared with attendees of a press conference held on June 15 by manufacturing equipment manufacturer TRUMPF, Ditzingen, Germany, in conjunction with the Paris Air Show.

“Aircraft have to become lighter, and the burning of fuel must become more efficient,” said Richard Bannmüller, CEO of TRUMPF Laser- und Systemtechnik GmbH. “Additive manufacturing is already playing a wide role in this, and that role will become more and more important.”

Aircraft manufacturers and suppliers are striving for carbon neutrality, which can only be achieved by increasing efficiency and adopting new fuels.

“It’s now possible to make parts lighter by design with 3D printing, parts that cannot be generated by milling, turning, stamping, or other classic manufacturing approaches,” Bannmüller said. “Also, the repair of parts such as engine blades is only possible using laser metal deposition [laser cladding]. This can be very helpful and save a lot of money for the aircraft industry. Our technology is being used for these types of applications already.”

By repairing cost-intensive components, the aerospace industry can save up to 80 per cent in costs compared to purchasing new ones.

Although the company mass produces laser welding and laser deposition machines, its laser technology, beam shaping technology, and sensor technology also is used by other machine builders to support the aerospace industry, Bannmüller explained.

“The space industry has one dedicated part that is printed nowadays exclusively–the thruster, which mixes the fuels,” said Bannmüller. “Most likely, the next lunar landing module will depend on our technology being used to build its thrusters.”

Bannmüller noted that more additive-manufactured parts for airplanes and helicopters are being certified.

“We find these parts mainly in the engine,” he noted. “However, handling structures for opening and closing doors are more and more generated by 3D systems because you can create structures that are much lighter than parts made from solid material. In seating structures as well, the use of additive also provides advantages in terms of weight reduction.”

The adoption of electric engines for shorter flights also will become key for carbon neutrality, and hydrogen may be an important enabler for electric drives in these aircraft, in terms of electricity storage and specific battery designs.

Laser welding of bipolar plates for hydrogen fuel cells is an area that TRUMPF is already supporting for the development of long-haul trucking needs. The welding of bipolar plates is difficult, and all the welds must be perfect because hydrogen is a very small molecule that can slip through any cracks.

“Extremely high speeds are necessary for these weld seams because a lot of welding is involved to weld together two bipolar plates,” said Bannmüller. “Meanwhile, our sensor technology enables it to guarantee that it is completely tight. If bipolar plates are not sealed off completely, the plates are useless.”