Reshaping Aircraft Structural Parts Manufacturing

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Relevant Industry Trends:

In the aerospace sector, there's a growing demand for lightweight yet robust components to enhance aircraft performance and efficiency. Manufacturers seek innovative solutions to replace traditional metal parts with lighter alternatives without compromising strength.

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Industry Challenge and Needs:

One significant challenge in aerospace manufacturing is the need to develop components that are both lightweight and durable. Conventional methods struggle to achieve this balance, hindering part performance and reproducibility. Manufacturers require a solution that can optimize part design and manufacturing processes to meet stringent aerospace standards.

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How We Solve It:

At 9T Labs, we address the challenge by leveraging Additive Fusion Technology™ (AFT) to produce high-performance thermoplastic parts. In collaboration with the University of Applied Sciences Northwestern Switzerland (FHNW), we undertook a project to develop a helicopter door hinge. By imitating the geometry of the steel part and optimizing it for CFRTP (carbon fiber-reinforced thermoplastic polymer), we aimed to outperform both steel and conventional CFRP hinges.

To print such a complex part, we employ a multibody strategy, dividing the part into four subparts to fully exploit continuous fiber printing. The AFT process fuses these subparts together, ensuring high quality and reproducibility required for series production. Through topology optimization and controlled fiber layup, we enhance mechanical values by up to 200%, demonstrating the potential to substitute load-carrying metal parts with lightweight CFRTP alternatives.

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The Outcomes Achieved thanks to Additive Fusion Technology™:

The final molded CF/PEKK hinge weighs only 28 grams, 75% lighter than the benchmark steel hinge, while achieving significantly improved mechanical values. With a yield point of 6.9 kN, our hinge surpasses both the steel part and previous CFRP solutions, showcasing the effectiveness of our innovative manufacturing approach.

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Want to Know More?

Discover how 9T Labs' AFT and smart factories can support your production and industrialization of thermoplastic high-performance parts. Contact us to explore how our technology can revolutionize your aerospace manufacturing processes.

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