Innovative technology: New machine for additive manufacturing at Liebherr-Aerospace in Campsas

Liebherr-Aerospace has invested in a new, state-of-the-art multi-laser machine for additive layer manufacturing (ALM) at its site in Campsas, near Toulouse (France).

The new machine uses the laser powder bed fusion (L-PBF) process. This involves applying fine metal powder in layers and melting it with a precise laser. The laser follows the contours of the 3D model, enabling the production of complex components with dimensional accuracy and without additional tools.

Manufacturing process with significant advantages

Liebherr-Aerospace has been using additive manufacturing (AM) for several years. The main interest of additive manufacturing is to add new functions to existing products, in addition to the capability to improve the design and the integration on board an aircraft. At the same time, AM helps reduce production lead times wherever feasible.

Components reliability can be increased through the use of high-performance materials. AM also simplifies the manufacturing flow chart by removing process steps and minimizing material waste. It enables the production of complex shapes that can consist of fewer parts than conventional components. This reduction in weight leads to lower CO2 and NOx emissions.

Thanks to this new machine in Campsas, which features multi-laser capabilities and improved ergonomics, productivity is further increased and operator interventions are easier.

From the printer to the sky

Liebherr started with AM already back in 2010 and since then, has continuously made significant investments evaluating and testing it, which makes the company one of the pioneers in the aviation industry. Whereas its facility in Campsas, near Toulouse (France), masters nickel based and aluminum alloys for air management systems such as heat transfer equipment, valves and turbomachinery, the facility in Lindenberg (Germany) handles R&D activities with AM manufactured titanium components for landing gears, flight controls and hydraulic systems.