GKN Aerospace is to lead two collaborative additive manufacturing (AM) research programmes, AIRLIFT and DAM and will inject its unique Laser Metal Deposition by wire (LMD-w) AM technology in them. AIRLIFT and DAM are focused on making AM serial production ready at high rates and explore how AM can do it for high value, high complexity product manufacture.

AIRLIFT (Additive Industrialisation for Future Technology) and DAM (Developing Design for Additive Manufacturing) are jointly supported by GKN Aerospace, ATI (Aerospace Technology Institute) Programme, Autodesk and Siemens Digital Industries Software and will bring together the expertise of universities, research institutes and industry. Forty highly specialised engineers and operators will work together on the programmes, which will be based out of GKN Aerospace’s recently announced £32 million Global Technology Centre in Bristol, said the company in a press release.

The aim of the projects is to accelerate industrialisation and increase GKN Aerospace’s market share in the growing global AM market.

Being a global leader in AM with AM components on seven flying platforms, DAM and AIRLIFT will be built on GKN Aerospace’s global AM expertise and infrastructure as well as on previous successful ATI programmes. Innovative simulation solutions, Industry 4.0 processes and new design tools and methods will add real value to aerospace customers by speeding up and customising product design and development, while maintaining the best possible quality.

AIRLIFT is a £19 million technology industrialisation programme that uses Industry 4.0 and simulation competencies to enhance both laser metal deposition with wire (LMD-w) and powder bed AM technologies.

DAM is a £14 million programme aimed at developing the next generation of design tools and methods for additive manufacturing using a data driven, material centric approach.

“AM is a strategic technology for the aerospace industry that will fundamentally change the way we design and manufacture aircraft. AM enables us to control material characteristics enabling benefits in terms of product performance, cost and environment. With AIRLIFT and DAM and the Global Technology Centre in Bristol, GKN Aerospace will further develop and industrialise additive manufacturing within the UK industrial and scientific eco-system. The ATI is an incredibly valuable resource for UK aerospace and we are delighted they are supporting this project to help the UK stay at the forefront of this exciting and emerging technology as part of the UK’s industrial strategy,“ said Russ Dunn, CTO and head of strategy, GKN Aerospace.

“The ATI is delighted to support GKN Aerospace’s AIRLIFT and DAM projects. These exciting projects will progress additive manufacturing technology, extending the capabilities for large scale AM component manufacture for the UK. This offers great opportunities for efficient future aircraft structures with tailored properties as well as valuable material and energy savings. These investments in GKN’s new Global Technology centre will strengthen the UK’s position in AM and establish a route to industrialise Laser Wire Deposition for aerospace,” said Dr. Simon Weeks, chief technology officer of ATI. (PC)