Hexagon and Nikon SLM collaborate to create 75% lightweighting with successful AM A330 Fuel Air Separator prototype production
19 November 2024
Frankfurt, 19th November 2024 – Hexagon’s Manufacturing Intelligence division and Nikon SLM have collaborated to redesign a large fabricated aircraft fuel system component using design freedom of additive manufacturing. Using Hexagon’s simulation-led Design for Additive Manufacturing (DfAM) toolchain and Nikon SLM’s advanced multi-laser metal additive manufacturing technology achieved significant lightweighting, part consolidation and precise geometric tolerances.
Airbus Operations used the technology from its partners to redesign a Fuel Air Separator – a component that feeds the Airbus A330’s Auxiliary Power Unit (APU). The combination of Hexagon’s software and Nikon SLM’s additive manufacturing technology has enabled the production of the simplified, more efficient AM A330 Fuel Air Separator prototype. This re-design achieved a 75% weight reduction from 35kg to less than 8.8kg, setting a new precedent for use of additive manufacturing and simulation-driven design in the aerospace industry.
The fuel air separator is a large, complex component that removes air from the APU fuel feed system, ensuring the APU can power essential aircraft systems when the main engines are off. The conventional part is fabricated from more than 30 individual components that require manual welding and assembly. This process is labour-intensive, which results in long lead times, and limits the potential for design improvements.
Airbus Operations and Nikon SLM initiated the research case study to optimise the production and performance of the air separator, creating an innovative process that used Nikon SLM's latest NXG XII 600 system – a large-format, multi-laser 3D printer – to simplify manufacturing, reduce lead times and streamline installation.
Simulation-driven redesign unlocks design freedom
The team called upon Hexagon to redesign the part using a Design for Additive Manufacturing (DfAM) workflow to maximise the potential of the advanced 3D printing system. Using Hexagon’s MSC Apex Generative Design software, they consolidated over 30 individual components into a single lightweight part that met all necessary structural and performance standards. Hexagon’s Simufact simulation tools were then used to optimise the printing process and predict part deformation, ensuring that precise geometric tolerances were maintained. Global tolerances were controlled to +/- 5 mm, with critical functional surfaces refined to +/- 0.5 mm to ensure seamless compatibility with the aircraft’s fuel system.
Simulation-driven design allowed for part optimisation while adhering to the stringent aerospace regulatory requirements. The additive manufacturing technology employed significantly reduced lead time by combining multiple manual processes and reducing production time. The large part was produced in just 68 hours, using optimised print data from Hexagon’s AMSTUDIO build preparation software to fully utilise the NXG XII 600 powder bed fusion printer and maintain precise geometric accuracy.
Advanced manufacturing drives sustainability innovation
The reduced part weight, decreased manufacturing lead time and enhanced efficiency gained through the manufacturing process contribute to lower fuel consumption.
The collaboration between these industry leaders has simplified production, enhanced performance, and set new benchmarks for efficiency. This project demonstrates the power of combining additive manufacturing with simulation-driven design, and Airbus is well-positioned to expand these technologies in future aircraft designs.
The full case study and video commentary is available at https://nikon-slm-solutions.com
Notes to editor
High resolution photography of the 3D part is available in JPEG or TIFF format.
For aircraft photography please visit the Airbus media centre https://mediacentre.airbus.com
About Nikon SLM Solutions
Nikon SLM Solutions AG is a global provider of integrated metal additive manufacturing solutions. Leading the industry since its inception, it continues to drive the future of metal AM in every major industry with its customers’ long-term success at its core. Nikon SLM Solutions is home to the world’s fastest metal additive manufacturing machines boasting up to 12 lasers and enabling build rates of up to 1000ccm/h. With a portfolio of systems to suit every customer's needs, along with its team of experts closely collaborating at every stage of the process, Nikon SLM Solutions leads the way on return on investment with maximum efficiency, productivity, and profitability. Nikon SLM Solutions believes that additive manufacturing is the future of manufacturing and has the desire and capability to take its customers there – right now.
Nikon SLM Solutions AG is a Company headquartered in Germany, with offices in Canada, China, France, India, Italy, Japan, Singapore, South Korea, and the United States.
Further information is available on www.nikon-slm-solutions.com.
Hexagon is the global leader in digital reality solutions, combining sensor, software and autonomous technologies. We are putting data to work to boost efficiency, productivity, quality and safety across industrial, manufacturing, infrastructure, public sector, and mobility applications.
Our technologies are shaping production and people related ecosystems to become increasingly connected and autonomous – ensuring a scalable, sustainable future.
Hexagon (Nasdaq Stockholm: HEXA B) has approximately 24,500 employees in 50 countries and net sales of approximately 5.4bn EUR. Learn more at hexagon.com and follow us @HexagonAB.