Manufacturing Of 3D Printed Metal Components For Helicopter Drive System

Abstract

This paper unveils the manufacturing processes and entailed challenges related to the 3D printing of metal parts for aerospace purposes, presenting two distinct case studies. The first case study examines the design and fabrication of lightweight components of the input module of a tilt-rotor drive system (Next Generation Civil Tilt-Rotor - NGCTR - Technology Demonstrator), representing a pioneering application of Additive Manufacturing technologies in aeronautics. Besides these functional components which comprise auxiliary lubrication tanks and pump cases, metal Additive Manufacturing has also been adopted to realize a scaled model of the whole gearbox of the tilt rotor, for dissemination purposes, proving the accuracy, flexibility and short lead times that such digital manufacturing process can offer. By analyzing this second case study, we aim to demonstrate the advantages and challenges associated with different AM technologies in aerospace applications, providing insights into their potential for future advancements.