The time and material savings are expected to make SMD an attractive option for the manufacture of large aerospace parts.
SMD is ideal for use in prototype production as well as in manufacturing, eliminating the need for tooling and shortening development lead-times, reducing aircraft development and operating costs. Near-net manufacture will slash part costs as currently up to 90% of the material is removed. Operational costs will be affected as SMD will allow complex, hollowed components to be manufactured that couldn’t be produced in any other way, allowing lighter aircraft to be built and reducing fuel costs.
SMD uses no tooling (flexible tooling), will be automated through RAPOLAC research, uses advanced methods to reduce costs (raw materials, machining time, cutting fluids, dies and moulds, tooling) and has low to zero harmful emissions.
SMD is expected to have a major impact on the design and production of parts and the repair of performance alloy components across a wide market base. Traditional methods such as forging or machining subtract metal from a work piece to get the desired shape. With SMD, this destructive, time consuming and costly process is reversed and material is progressively added to create a near-net shaped component, which needs minimal finishing. This means that effectively zero scrap rates are achieved. Because little or no tooling is required, design changes can even be accommodated after part build through further deposition or machining. SMD also allows more complex components to be built in comparison with methods such as casting, and hybrid components (parts which are manufactured using more than one technique or from more than one material) can also be created.
To generate wealth and ensure a high standard of living for its citizens, the EU will need a strong manufacturing sector, which is both environmentally friendly and competitive. RAPOLAC focuses on the manufacture of high value added components, such as aerospace engines and airframe sub-assemblies, making the manufacturing process more competitive by eliminating the need for tooling and substantially reducing raw material costs and finish machining, leading to a reduction in swarf, cutting fluids and the associated disposal costs. Substantial time-savings will be made because of the lack of tooling, reducing lead-times and allowing design changes to be made right up to the last minute and even beyond as changes can be made to parts simply by performing additional depositions, or machining.
Strengthening competitiveness
The aerospace industry is vital to meeting Europe’s objectives for economic growth, security and quality of life. It is directly associated with, and influenced by a broad range of European policies such as trade, transport, environment as well as security and defence . The goals set in ‘Vision 2020’ are very demanding and can only be attained via breakthrough technologies and radically new methods of manufacturing such as SMD. It is clear that major advances in manufacturing technologies will assist European companies to access global markets. RAPOLAC aims to win global leadership for European Aeronautics by allowing European manufacturers to dramatically reduce manufacturing costs (raw material, waste disposal) and development lead-times. SMD is ideal for use in prototype production as well as in manufacturing, eliminating the need for tooling and shortening development lead-times, reducing aircraft development and operating costs. Near-net manufacture will slash part costs as currently up to 90% of the material is removed from certain components. Operational costs will be affected as SMD will allow complex, hollowed parts to be manufactured that couldn’t be produced in any other way, allowing lighter aircraft to be built and reducing fuel costs. It uses no tooling (flexible tooling), will be automated through RAPOLAC research, uses advanced methods to reduce costs (raw materials, machining time, cutting fluids, dies and moulds, tooling) and has low to zero harmful emissions.
Community societal objectives:
People are concerned for the environment and want factories to produce fewer emissions and less waste and to dispose of any excess material in a responsible fashion. SMD eliminates swarf and cutting fluids from the manufacturing process. A positive image of innovation-oriented research will be formed as a result of the new, greener products produced due to the take-up of SMD through RAPOLAC. The strong links between the partners and large aerospace suppliers will ensure the take-up of SMD once its benefits have been proven. It will also ensure that the full benefits of any breakthrough technologies are translated into practical applications and a framework for “manufacturing in 2010” will be provided. Partners are aware of the Science and Society Action plan, and are dedicated to help in the formation of a pool of scientific researchers to ensure socio-economic development.
Safety and working conditions:
The technologies developed through RAPOLAC will contribute to a safer working environment. The development of process control systems for SMD will lead to better operator working conditions and more user-friendly machine interfaces, as well as improving safety as the there is less human interaction with the machine. Automation will reduce long-term medical conditions brought on, for example, by standing and watching the welding process for long periods of time. Near-net shaped parts will significantly reduce the amount of material which needs to be removed (for some parts, over 90% of the forging is removed via machining), reducing swarf and cutting fluid usage. Cutting fluid is carcinogenic, and prolonged exposure can also lead to skin and respiratory diseases.