Full-Process From Design to Production Of Additive Manufacturing Components

This study presents an extensive, cross-functional framework that governs the entire life cycle of components produced using additive manufacturing (AM), from initial business concept to actual production. It offers a thorough examination of the current AM landscape, covering its historical evolution, classification of various techniques, and a detailed explanation of AM processes. The second chapter delves into the reasoning that drives companies to invest in AM components, with a strong emphasis on the goals of enhancement and optimization. The third chapter dissects the design development into three distinct phases: high- level design concept, preliminary design, and detailed design intricacies. The fourth chapter explores the complexities of aerospace certification for AM components, elucidating the fundamental principles of the TC, procedures for potential modifications, and classifications of changes. This chapter also lists the prerequisites for certification, providing explanations for each requirement. Additionally, it details the progression of certification through workshops conducted by EASA and FAA, accompanied by comprehensive explanations of the associated Certification Memoranda. The fifth chapter emphasizes the intricacies of the production process, particularly focusing on adhering to applicable company technical specifications. The sixth chapter provides an example of a product built through Additive Manufacturing in the certification phase. The final section underscores the advantages of AM, notably in terms of weight reduction and complex geometries. Nevertheless, it also acknowledges the certification challenges, along with the associated significant financial costs. Nonetheless, it highlights the paramount importance of such corporate investment in cultivating valuable in-house expertise and demonstrating this expertise to the relevant authorities, ultimately showcasing the progress through the certification and the subsequent reliability achieved in the production of various components.