Laser Fusion Core for Complex Composite Aeronautical Parts
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of complex aeronautical parts, such as tubular pipes, requires numerous and costly tools and materials that must meet strict safety standards for fire, smoke, and toxicity, while traditional manufacturing processes are inefficient in reducing costs and achieving complex geometries.
Innovation Solution
A process involving a three-dimensional laser fusion process to create a core part with a PEEK resin, followed by wrapping it with fibers impregnated resin, using methods like draping or resin transfer molding, to produce parts with complex shapes without the need for extensive tooling and meeting safety standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manufacturing processes are used to produce complex aeronautical parts, then the parts can be produced with established methods, but the production costs increase and the geometric complexity is limited
Solution Approach 1:
The manufacturing process is segmented into two distinct phases: first producing a core part with the complex internal geometry using laser fusion, then adding the outer shell with fibers and resin. This segmentation allows each phase to optimize for its specific function - the core for geometric complexity and the shell for mechanical strength - thereby achieving high geometric complexity without proportionally increasing production cost
Solution Approach 2:
The core part created by laser fusion is nested within the outer shell formed by fiber reinforcement and resin impregnation. This nested structure allows the complex internal geometry to be created first, then protected and strengthened by the outer layer, enabling geometric complexity that would be difficult or impossible to achieve with traditional single-step manufacturing while controlling overall production cost
2Manufacturing precision
If numerous tools are used to produce complex parts with traditional processes, then the parts can be manufactured, but the non-recurring costs increase
Solution Approach 1:
The complex internal geometry is extracted from the traditional tooling-dependent process and created independently by the laser fusion process. This extraction eliminates the need for complex molds and tools that would be required to form such geometries with traditional methods, thereby reducing device complexity and non-recurring costs while maintaining manufacturing precision
Solution Approach 2:
The mechanical tooling system is replaced with a laser-based energy field system for creating the core part. Instead of using physical molds and mechanical forming tools, the laser fusion process uses concentrated optical energy to selectively fuse powder material, eliminating the need for complex tooling while achieving high geometric complexity
3Adaptability or versatility
If parts are made in multiple segments and assembled, then the manufacturing flexibility increases, but the assembly complexity and recurring costs increase
Solution Approach 1:
The core part produced by laser fusion and the outer shell with fiber reinforcement are merged into a single integrated component through the impregnation and curing process. This merging eliminates the need for separate assembly operations while maintaining the flexibility to produce complex geometries, thereby reducing assembly complexity and recurring costs without sacrificing manufacturing adaptability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production costs and simplifies the manufacturing and assembly of complex parts, enabling the creation of shapes that were previously unachievable while ensuring compliance with aeronautical safety standards, using PEEK resin's high-temperature properties and mechanical strength.
Implementation Method 1
The three-dimensional creation process is a laser fusion process (SLS)... a selective laser sintering (heating and fusion) technique without liquid phase... using the energy of a laser to cause the local fusion of a powder
Implementation Method 2
a selective laser sintering (heating and fusion) technique without liquid phase... The laser consolidates the wafer on the surface of the preheated powder bed
Data Source
Figure 1~3
Figure 4
AI summary
The invention relates to a method for making parts (6) having a complex geometrical shape, said geometrical shape including e.g. various bends, branching, deflectors, sections or thickness, that includes the steps of: forming a core part (1) having a geometry substantially similar to that of the target shape, except for the outer thickness, using a three-dimensional creation method; wrapping at least a portion of said core part with fibres previously or subsequently impregnated with resin until the final dimensions of the target shape are reached; and curing the resin.