Additive Manufacturing takes flight

26 February, 2025

Solution

“Our relationship with Renishaw goes way back, and we first came to the UK to meet with its CEO in 2018,” explained Campbell. “The reason we decided to go for a Renishaw system is the brand—it’s a trust marker, and we knew it was a company that offers excellent engineering and process capability. Its RenAM 500 series are world-class AM machines, and of the quality we needed to achieve FAA certification.”

Tronosjet purchased three RenAM series machines from Renishaw: the AM250, the 500S Flex, and the 500Q. All three machines use laser powder bed fusion (LPBF) technology for metal component production and feature a build volume of 250 mm x 250 mm x 350 mm. The AM250, a single-laser system, was selected to produce the thrust control pulley bracket due to its ability to produce parts with high material properties that meet FAA standards. Notably, the decision to avoid multiple lasers or recycled powder reflected a cautious approach to align with FAA expectations.

Using the AM250, Tronosjet printed the bracket from a Ti-6Al-4V titanium alloy. Titanium’s high strength-to-weight ratio and corrosion resistance make it a popular choice for aerospace components, as well as for high-pressure hydraulic and pneumatic systems.

Result

After extensive testing, the titanium bracket proved to be five times stronger than the original magnesium part. It survived loads exceeding 22,000 lb, compared to the original’s failure at 4,000 lb. The part underwent rigorous NDT, static, functional, and destructive testing to validate its performance, convincing FAA regulators of its safety and reliability.

“The numbers put things into perspective,” continued Campbell. “The bracket’s superior tensile strength shows that the titanium print is capable of withstanding significantly higher loads than required when the aircraft is in flight. This helped convince the regulators that AM was more than up to the job.”

The FAA certified the bracket under its Parts Manufacturer Approval (PMA) programme, making it one of the first FAA-certified metallic AM components. Certification allows Tronosjet to produce and supply the part to customers, providing a competitive edge in the aerospace market.

Implications for hydraulic and pneumatic systems

The success of Tronosjet’s additive manufacturing process signals broader opportunities for using AM to produce highly customised components for hydraulic and pneumatic systems. Lightweight manifolds, intricate valve systems, and pressure-resistant housings could all benefit from the precision and material properties achievable through LPBF technology. As regulatory bodies continue to recognise the reliability of AM parts, its application in fluid power systems for aerospace and other industries will likely expand.

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