DEPOSE - Additive manufacturing of cabin monuments using Direct Energy Deposition

 

Motivation

Aircraft cabin partitions are commonly made in sandwich design consisting of a lightweight core and two cover layers of fibre-reinforced plastic composites. The critical points of these structures are the load introduction points. For this purpose, so-called inserts with a potting compound are integrated into the structure. For larger loads, hard fabric blocks are used. A suitable design for the load path is only possible to a limited extenn, so that overdimensioning is occurring.

 

Objective

The aim of the sub-project is to develop a mechanically and structurally optimised aircraft cabin partition, which is intended to be manufactured in one piece on the basis of the laser-based DED (Direct Energy Deposition) process in order to replace previous sandwich laminate constructions. The focus of the Institute of Product Development and Mechanical Engineering Design at TU Hamburg is on the design of this structure, taking into account the restrictions and safety factors caused by the manufacturing process. At the end of the project, a complete, large-scale demonstrator (size approx. 2000 x 1200 mm) should be manufactured.

 

Research Method

The component geometry should be structurally optimised with regard to an optimal load-weight ratio through iterative, software-supported processes, e.g. by topology optimisation, and then validated through various static and dynami tests. Starting from the characterisation of the mechanical and geometric properties, the results are successively transferred to higher component complexities according to the Building Block Approach. In addition, the influences of process optimisations on the part will be investigated. Finally, a full-size test is carried out on the Hexapod test bench and the knowledge gained is used to derive rules and guidelines for the production-appropriate design for the manufacture of DED-based structures.

Project Organisation

Project Lead (PKT): Prof. Dr.-Ing. Dieter Krause

Project Execution: Tobias S. Hartwich, M.Sc.

The project is part of the  Field of Application Aviation.

Funding and partner

The project is funded by the Federal Ministry for Economical Affairs and Energy (BMWi) as part of the sixth Federal Aeronautical Research Programm (LUFO VI-1). The project started in July of 2020 and will continue until September of 2024.

Partner is the ERLAS Erlanger Lasertechnik GmbH.