Case Study: Airbus Helicopters saves development costs with the German RepRap x400

Production using additive manufacturing in the aerospace industry brings many advantages. Airbus Helicopters use their German RepRap x400 3D printer in the development field to ensure deadlines, cost and quality goals. In a recent case, it's about validating the design of an integral new step.

Frank Singer, Head of Department Vehicle System Installation at Airbus Helicopters in Germany GmbH explains: "It happens again and again that a crew member of a helicopter stands outside on the runners during the flight due to operational reasons. Under certain circumstances, also during operation of the rescue winch. The relatively small footprint on the runners could be optimized by using a step."

In a first step, the nearly three-meter-long model will be subdivided into printable individual parts. Afterwards the individual puzzle plug connections are constructed.

x400 with puzzle part

"In the past, we have had to divide larger prototypes into separate parts because of the print bed size. These were often glued together. However, this was always associated with further processing steps, which we can now save - if the application allows it. The quickly printed parts require no further processing steps or curing time of the adhesive anymore" says Frank Singer. "With this method, we have found an ingenious application for this design, to have a large component quickly and cost-effectively available with the print bed size that is available."

For Airbus Helicopters, the new plug-in connection, for appropriate applications, is an optimal solution because it requires no glue, no screw connection or tools. The plug connection can be used at least 50 times without any signs of wear. The model is much more stable than it would be in a glueing process. It withstands it’s own weight of 3.9 kg without any problems and can be mounted on the helicopter for illustrative purposes without wobbling or even loosening or falling off. PLA was used as the material can be easily and quickly processed and there were no further requirements for the component.

Airbus Helicopters use their German RepRap x400 3D printer especially for the so-called "FIT Check". All designed parts are printed as prototypes. With these parts, the installability and the fitting for the helicopter are checked. Possible changes and adjustments can be easily transferred to the series parts with little effort.


Tail and connecting part

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