This project seeks to explore the range of production variability that occurs with repetitive fused deposition modelling (FDM) of aircraft components. Air New Zealand is currently exploring the 3D printing of interior, non-structural components in ULTEM 9085 (Aerospace Grade) to reduce component lead time, reduce production costs, and increase flexibility. CAANZ regulations require all interior components on board aircraft to pass flammability requirements. 3D printed parts are known for their imperfect repeatability as a result of component, material, and machining variations. It is unknown whether this component to component variation has any effect on the flammability of the produced components. It cannot be proven that just because one component passes the flammability requirements that all components produced are safe for use aboard aircraft. As a result, the CAANZ will not authorise the use of these 3D printed components aboard aircraft in New Zealand at this time.
Air New Zealand has insufficient experimental data to conclusively prove that variability between components has no effect on their flammability. They have requested that an investigation be carried out to prove whether the variation in FDM components has any effect on the flammability, and to develop methods to identify the degree of variation in production batches of components. Should it be shown that the variation has limited to no effect on the flammability of the components and a small batch of components pass the Industry Standard ‘Burn Test’ certified by standard FAR 25.853, the CAANZ may approve the use of FDM components in aircraft interiors.
This investigation will develop the experimental data required by Air New Zealand and the CAANZ in the certification of FDM parts. Machine set-up parameters, primarily extrusion speed, part geometry, feed rate, nozzle temperature, and layer thickness result in operator induced variation. Test samples will be printed with a range of operator induced variation and tested using the vertical burn test certified by standard FAR 25.853 to measure their flammability. This will provide insight into the variation in flammability as a result of these parameters, and allow acceptable limits to be defined for repetitive manufacture. This investigation also has the capacity to expand to acoustic and structural variability in repetitive component manufacture, however this is not a focus of this investigation. The results of this investigation could ultimately set guidelines for future component development for use on aircraft.
Undergraduate
None
CACM - Strength of Materials Lab (Newmarket 902 Lvl 3, Lab)