On-site spare part production for aircraft

AM, which sequentially adds layers of material according to specifications in a computer-aided design file, has progressed tremendously since its inception for small batches of custom-designed parts. Its application to the maintenance, repair and overhaul (MRO) process in the aerospace industry is a promising way to cut costs, downtime and scrap. The EU is supporting development efforts and activities carried out in the project 'Future repair and maintenance for aerospace industry' (REPAIR).

With only raw material stored rather than millions of spare parts, less capital is locked up and potentially wasted. The energy consumption associated with production of all those spare parts is eliminated. Scientists plan to demonstrate the benefits of making new parts rather than buying them to improve the cost efficiency of MRO processes in aeronautics and air transport.

Within the first project period, the team defined the information technology (IT) management platform and the planned production system. The team has established a classification system for AM particular to aerospace parts that will aid in suggesting the best repair options. A basic structure for the certification part of the IT programme has been developed.

Project partners evaluated their manufacturing processes and identified the main cost drivers to be included in the decision support tool. Importantly, the consortium identified four future scenarios to include indicators related to the likely evolution of AM to ensure the decision support tool will remain relevant.

Scientists have selected sample parts and developed the test rig. A clamping device and in situ control system are under development as is software to integrate the laser cladding process.

REPAIR technology promises numerous benefits, including a significant reduction in MRO costs and time, job creation, reduction of scrap and energy consumption, and enhanced aircraft safety. Innovative application of AM to on-site maintenance and repair is an idea ready to take flight.