Aerospace Garage

Upskill / Aerospace and Space / Additive manufacturing in aviation and aerospace

Additive manufacturing in aviation and aerospace

Processes, materials, design, defects, post-processing, CT inspection and qualification under EASA and FAA practice, with engine, cabin, MRO and space applications

By Aerospace Garage Desk · Practitioner · 50 minutes · 24 narrated pages

What you will be able to do

  • ✓ Name the ISO/ASTM 52900 process categories and match powder bed fusion, directed energy deposition, material extrusion and binder jetting to aerospace uses.
  • ✓ Select materials and apply design for additive manufacturing, including topology optimisation, part consolidation, support strategy and build orientation.
  • ✓ Explain how porosity, lack of fusion, residual stress and surface roughness arise, and plan a post-processing route including stress relief, HIP and machining.
  • ✓ Apply CT inspection with proven capability and zone-based acceptance criteria, within a frozen, qualified process.
  • ✓ Describe how EASA (CM-S-008) and the FAA certify additive parts under the existing materials, fabrication and design value rules, using SAE AMS specifications, and draw lessons from the AAIB G-BYLZ investigation.
  • ✓ Build a cost, buy-to-fly or consolidation business case for a printed part in aviation, MRO or space.

Course content

Session 1 · What additive manufacturing is

1.1

  1. Building parts layer by layer · free preview
  2. The process families by their standard names
  3. Where additive manufacturing fits, and where it does not
  4. Worked example: build time and cost per part
Session 2 · Materials and design for additive manufacturing

1.2

  1. Metals: titanium, nickel and aluminium alloys
  2. Polymers: high-performance thermoplastics
  3. Design for additive manufacturing
  4. Worked example: buy-to-fly against machining
Session 3 · Defects and post-processing

1.3

  1. How defects form
  2. Residual stress, distortion and surface roughness
  3. The post-processing chain
  4. Worked example: planning the post-processing route
Session 4 · Inspection, CT and process control

1.4

  1. The inspection toolbox
  2. Computed tomography
  3. Process control and the quality system
  4. Worked example: a CT porosity acceptance decision
Session 5 · Qualification and certification

1.5

  1. The certification rule base
  2. EASA's certification memorandum on additive manufacturing
  3. The FAA approach and industry specifications
  4. From the investigation file: a printed elbow on G-BYLZ
Session 6 · Applications in aviation, MRO and space

1.6

  1. Engines and airframes: what has flown
  2. Cabin, tooling and the maintenance shop
  3. Space: rocket engines and spaceflight standards
  4. Worked example: a part-consolidation business case

Who this course is for

Upskill courses are for professional development and are not approved by any aviation authority. Learner Terms

Course content © Aerospace Garage Limited. All rights reserved.