Applying design for additive manufacturing to existing aerospace parts

Abstract

Additive Manufacturing has widely been used in the aerospace industry. However, local uptake in the aerospace industry has been slow with mostly additively manufactured polymer parts being used. The Advanced High Performance Reconnaissance Light Aircraft (AHRLAC), which is a locally produced military aircraft, is well positioned to prove the local capabilities in Metal Additive Manufacturing to the local Aerospace industry. Two parts of this aircraft were identified through prior experience in Additive Manufacturing and taken through the Design for Additive Manufacturing process. The identified parts were a forward cockpit control cable mount and a canopy guide. The parts were redesigned using topology optimisation and, in both instances, a weight, cost, and lead time reduction was achieved.