IRNITU Utilises 3D Printing for Manufacturing Tooling for the Aerospace Industry

Photo by © Irkutsk National Research Technical University (IRNITU)

The development and implementation of additive technologies in aerospace manufacturing is a pertinent issue, aimed at enhancing the efficiency of production processes. Specifically, staff at the Irkutsk National Research Technical University (IRNITU) are using 3D printing to create polymer tooling for use in the forming of sheet metal components for aircraft structures.

“The use of a plastic mould reduces the time required for production preparation compared to traditional methods, where metals such as aluminium or steel are used as tooling materials. A prototype manufactured by IRNITU engineers demonstrated the ability to withstand the forming of a 1.5mm thick aluminium blank, which confirms the technology’s viability,” the university stated.

The proposed 3D printing method differs from the traditional solid moulding of a model. The assembly of the polymer tooling is completed in 12 hours, which is four times faster than manufacturing an equivalent part by solid printing, a process that takes 48 hours. The project is being carried out by the “Digital Technologies for Manufacturing Polymer Composite Products” research laboratory, led by Yuri Ivanov, whose team includes a research engineer, a research laboratory assistant, and a training instructor.

According to research laboratory assistant Lev Shemetov, plastic 3D printing is a promising technology for aerospace, as the creation of steel or aluminium tooling involves time-consuming machining. Specialists from the Irkutsk Aviation Plant, a subsidiary of PJSC Yakovlev, have expressed interest in these new methods of tooling manufacture. The plant’s staff are particularly concerned with the strength characteristics and service life of the developed tooling, which necessitates further research.

The laboratory team have implemented a technical solution involving the use of thermosetting polymers, capable of setting like concrete, to fill the mould. In experiments with the filling technology and special fillers, glass, graphite powder, and aluminium powder were tested. The primary objective was to select the optimum composition which would ensure minimal deformation of the mould under high loads. The test results demonstrated that the 3D-printed plastic mould successfully withstands the working loads of the press. The proposed manufacturing process allows for the production of tooling in a shorter time and at a lower cost.

In the future, there are plans to present the project to the Irkutsk Aviation Plant to obtain feedback from manufacturing staff and to determine the feasibility of implementing the technology in the serial production of sheet metal components. The study of operational parameters and service life characteristics will enable a full understanding of the method’s potential in industrial settings, optimise the technology, and adapt it to the needs of serial production of aerospace parts.

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