As a company in constant search of leading methodologies to deliver better products, better experiences, and better cost-value benefit, Emirates began exploring 3D technology in 2014 and identified interior cabin parts as a fertile testing ground for bringing 3D plastic production on board.
“At Emirates there is a strong focus on operational efficiency. Even a small reduction in weight of a single cabin component can have a significant impact when compounded over our fleet of over 265 aircraft and can lead to reduced fuel emissions and associated costs. The opportunities and potential for lighter weight parts are staggering.” said Ahmed Safa, Senior Vice President, Engineering Support Services at Emirates.
Safety first: materials matter
It should come as no surprise and great comfort that rigorous certification protocols are the gatekeepers to new innovation in aviation. Although Emirates was extremely interested in taking advantage of 3D printing for all the benefits additive technology offers in terms of weight reduction, lower operating costs and supply chain efficiency, these pragmatic interests always come second to safety. Therefore, after selecting to work with 3D Systems due to the company’s leading expertise in additive manufacturing and dedicated aerospace department, Emirates laid out the material and certification requirements that needed to be met for final 3D printed parts to pass inspection and be incorporated in the aircraft cabin.
Flame retardant nylon material, DuraForm® ProX® FR1200, a FAR 25.853 compliant, 10% lighter than the average aviation plastic was used. Designed for use with 3D Systems selective laser sintering (SLS) 3D printing help airline lower weight of in-cabin parts for significant operational cost savings opportunity.
Designing fit-for-purpose parts
Without preexisting CAD data on hand for video monitor shroud production, Emirates enlisted help from FARO Technologies using the FARO® Design ScanArm to collect point cloud data, and 3D Systems Geomagic Design X™ reverse engineering software to turn that data into a parametric CAD file ready for 3D printing. This scan-based design workflow enabled a more efficient and accurate design process that added agility to Emirates’ process.
What are their challenge and how 3D Systems helps them?
Challenge:
Reduce part weight for high volume, high turnover parts to improve operating efficiency and cost savings using materials that comply with stringent aviation standards.
Solution:
Fit-for-purpose parts delivered using reverse engineering and 3D Systems’ selective laser sintering (SLS) with certified DuraForm® ProX® FR1200 flame retardant nylon material.
Results:
- 9–13% weight reduction in SLS printed parts as compared to conventionally produced ones
- Significant cost savings introduced with every weight saving measure
- Potential for significant reductions in fuel emissions
- Flame retardant nylon passes certification for civil aviation
- SLS printing offers faster, cheaper alternative for delivering bespoke cabin parts with the potential to reduce inventory for increased supply chain efficiency