Information posted on February 1, 2021 (information updated on April 30, 2021; September 30, 2021; December 30, 2021; March 30, 2022; June 14, 2023; August 31, 2023; October 13, 2023; January 9, 2024)

Project number:

1.1.1.1/20/A/188

Project title:

Addressing the needs of the aviation sector by integrating 3D industrial printing solutions into existing supply chains.

Project leading partner:

SIA Baltic3D.EU

Project objective:

Conduct research on the application of industrial 3D printing (also referred to as layer manufacturing) for the serial production of aircraft interior components. The purpose of the study is to address the needs of the aviation industry by conducting an in-depth analysis of the potential of industrial 3D printing to become a reliable method for serial production, replacing traditional manufacturing methods. This thorough investigation will allow the evaluation of the potential for integrating layer manufacturing methods into the aviation industry’s supply chains.

The project will implement the following technical-economic feasibility studies, industrial research, and experimental development activities:

• Application research on 2 SLS technology materials by manufacturing test samples of these materials and conducting laboratory combustion tests (activity No.1.1 will be started before the contract with the collaborating institution is signed).

• Creation of design templates for 20 high-complexity aircraft interior finishing details to demonstrate the possibility of combining components, including grid and bionic design elements, and partial fill options.

• Assessment of series production readiness using FDM and SLS technologies, generating data from real production cycles, and evaluating the impact of part size and machine size on production costs and repeatability.

• Tests for automated series post-processing and tests for suitable material tests in real application cases.

• Analysis of CO2 emission changes using layer manufacturing technologies, and comparison of this analysis with traditional manufacturing technologies.

• Comparative analysis of FDM and SLS technologies under series production conditions, and comparison of these technologies with traditional manufacturing methods, comparing their processes step by step and corresponding production costs (activities No.3.1 and 3.2 will be started before the contract with the collaborating institution is signed).

• Overall industry assessment, as well as the evaluation of various industry players’ readiness to integrate layer manufacturing into their supply chains.

• Creation of a manual for assessing the potential application of series layer manufacturing.

Project implementation:

SIA Baltic3d.EU signed a contract with the Central Finance and Contracting Agency on March 26, 2021, for the implementation of project No. 1.1.1.1/20/A/188.

From February 1, 2021, to April 30, 2021, the following activities were initiated:

• Assessment of benefits by comparing internal manufacturing with outsourcing (implementation ongoing);

• Integration of layer manufacturing into the existing supply chain (implementation ongoing);

• Assessment of industry players’ readiness to integrate layer manufacturing into their processes (implementation ongoing);

• Analysis of the main driving forces of key aviation industry participants (implementation ongoing).

Activities were carried out by engaging an outsourcing service provider.

From May 1, 2021, to July 31, 2021, the following activities were implemented:

• Continued implementation of activities initiated in the previous period;

• Initiated research on SLS materials and suitable SLS technology systems to select the most appropriate materials for manufacturing aircraft interior parts;

• Started the development of high-complexity large-scale aircraft interior design templates for FDM technology;

• Initiated a comparison study of industrial 3D printing against traditional manufacturing methods.

From August 1, 2021, to December 30, 2021, the following activities were implemented:

• Continued implementation of activities initiated in the previous period;

• Selected parts, created initial designs that need to be improved to meet 3D printing requirements;

• Began developing a library platform for saving part files and tracking parameters;

• Received reports from the outsourcing service provider about the readiness of industry players to integrate layer manufacturing into their processes and the analysis of the main driving forces of key aviation industry participants.

From December 31, 2021, to March 30, 2022, the following activities were implemented:

• Continued implementation of activities initiated in the previous period;

• Began comparing the advantages of SLS and FDM technologies in the production of aircraft interior parts;

• Engaged a scientific leader for project implementation.

By March 31, 2023, the following actions within the project were completed:

• Developed designs for 20 aircraft interior parts, including 10 for FDM technology and 10 for SLS technology;

• Started developing prototypes of the designed aircraft interior parts (8 prototypes so far);

• Began analyzing opportunities for optimizing production parameters, conducting long production cycles (over 48 hours) - completed 12 production cycles;

• Performed a comparison of FDM and SLS technologies with traditional manufacturing technology (die casting);

• Conducted lifecycle tests of FDM technology materials, which also resulted in a scientific publication https://doi.org/10.3390/polym15020324;

• Completed studies on the readiness of industry players to integrate layer manufacturing into their processes and the analysis of the main driving forces of key aviation industry participants.

By June 30, 2023, project implementation continued:

• Decided to exclude SLS technology material testing from the project;

• Continued implementing remaining activities, replanning the implementation timelines;

• Continued developing the next scientific publication.

By September 30, 2023, project implementation continued:

• Proposed contract amendments, excluding some planned activities from the project and reducing the project-related costs to EUR 542,666.35;

• Continued implementing remaining activities;

• Published a second scientific publication on the impact of printing direction and post-printing conditions on the flexural properties of ULTEM 9085 (https://doi.org/10.3390/jcs7080316).

By November 30, 2023, project implementation concluded:

• Conducted burning tests of materials ANTERO 800 NA and ULTEM 9085 (in various colors);

• Developed a coloring methodology for post-processing 3D printed aircraft parts;

• Performed mechanical tests of parts;

• Continued implementing other activities.