Additive Manufacturing by Liebherr
Looking into the production chamber of the 3D printer in Lindenberg
Since 2017, Liebherr-Aerospace Lindenberg GmbH, Lindenberg (Germany) is one of just three companies in Germany to be authorized by the German Federal Aviation Office (Luftfahrtbundesamt, LBA) to produce flight components using the additive manufacturing technique. This great success means that Liebherr is a recognized pioneer and trusted partner in the aircraft world. Specific plans are already underway for the industrial launch of non-safety-critical mountings for landing gear sensors and flight control systems. In the medium term, more complex and also safety-critical components will be produced, which fully utilize the potential of additive manufacturing. Partly for this reason, the Lindenberg site acquired a second 3D printer.
Semi-finished valve bodies from Toulouse with production stands that are removed in a later processing step.
Liebherr-Aerospace Toulouse SAS, in Toulouse (France), is driving development forward with nickel alloy 718: a serial part from the 3D printer is currently undergoing qualification in an engine bleed valve on a regional aircraft program. The first deliveries of the equipment are scheduled for the end of 2018. The team in Toulouse also made parts from an aluminum alloy using the 3D printing process, with the result that Liebherr-Aerospace in Toulouse now has a wider available selection of 3D materials that are suited to its requirements. Furthermore, the company is working in partnership with a number of aircraft manufacturers on more complex and more critical high-value air system components, which could be offered for their future platforms.
Two sites – one common strategy
Both Aerospace sites are pursuing a common strategy across all their activities. The experts in Lindenberg and Toulouse are identifying a shortlist of components that could similarly benefit from additive manufacturing in terms of weight savings or multi-functionality. Both teams are working in close consultation with aircraft manufacturers – not only to enhance or develop new components, but also to streamline and optimize processes which is a key factor in cost-efficient production.
The Liebherr-Aerospace experts have their sights firmly set on the future milestones: additive manufactured components need to be ready to put into service in aircraft, and they are also working on producing more complex and flight-critical components, as well as external supplier qualification.
