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Video: Lufthansa Technik Relies On Additive Technology From EOS
At the end of 2015, EOS, provider of solutions in the field of additive manufacturing, introduced an extension of its EOS M 290 system for direct metal laser sintering (DMLS) with Eostate Meltpool. This should enable automated, intelligent process monitoring in real time - per melting point, per shift and per component. It creates the prerequisites for automatic monitoring of the weld pool and allows a view of the component during the construction process. In this way, a new quality system can be set up in the future.
System convinces with process stability
Lufthansa Technik is the first customer to have the complete solution. Udo Behrendt, Key Account Manager at EOS, says: "We are delighted to be able to welcome Lufthansa Technik as an industrial partner with whom we can further develop our technology for the high demands of the repair of aerospace components."
Simon Feicks, Project Manager Additive Manufacturing, Engine Services at Lufthansa Technik, explains: “We chose the EOS solution for several reasons. The underlying metal system EOS M 290 impresses with its process stability. The technology has proven itself with engine manufacturers. In the decision-making process, we were particularly impressed by this combination of core competencies. On this basis, we will prepare for future generations of components optimized for additive manufacturing in order to be able to defend our leadership position in the market.”
Complete quality control in the construction process
The powder-based process from EOS complements the already established Lufthansa Technik portfolio of additive manufacturing processes and is an important part of new repair processes with regard to future additive engine components. With Eostate Meltpool, the company is introducing an essential quality management component in the process, which should contribute to seamless quality control in the construction process. DMLS technology opens up new potential compared to other additive manufacturing processes used by the company: Netshape geometries and the implementation of internal cavities complement the repair portfolio.
In the field of engines, the company focuses on a hybrid repair approach. Feicks explains that one wants to prepare for the day when additively manufactured components of the new engine generations arrive in the engine repair shops so that these repairs can be offered to the customer in a cost-efficient and quality-optimized manner. He adds: “We are already seeing first successes in fixture construction. We were able to reduce lead times and cut costs. Nevertheless, this technology requires our mechanics, designers and engineers to rethink. For this reason, in addition to installing the system, the further training and support of our employees is an essential part of the full use of industrial 3D printing."
Feicks explains: “For us, additive manufacturing is a technology of the future. It's time to rethink. Milling from full was yesterday. Today, building is carried out selectively where it is needed. Resource efficiency also plays an important role. We no longer want to be restricted by tools. The boundaries of manufacturing variance are being shifted and we are looking into a future that we all still have to learn to understand.”(Kj)
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