Delcam and Renishaw to support GKN Aerospace in additive manufacturing project

In addition to Delcam, Renishaw and GKN Aerospace, the 3½ year, £13.4 million project also includes the Universities of Sheffield and Warwick, and is backed by the UK's Aerospace Technology Institute (ATI) and funded jointly by industry and the government's Technology Strategy Board (TSB). Horizon is part of a major investment of £154 million in research projects to keep the UK as a world leader in aerospace innovation and was announced by Deputy Prime Minister Nick Clegg during his visit to the 2014 Farnborough International Air Show. The project will take a number of promising additive manufacturing (AM) techniques from research and development through to viable production processes, with the aim of producing components that could be as much as 50% lighter than their conventional counterparts and which incorporate complex geometries that cannot be manufactured cost-effectively today. It is anticipated that these new processes will unlock innovations in low-drag, high performance wing designs and in lighter, even more efficient engine systems, and in doing so will lead to dramatic reductions in aircraft fuel consumption and emissions. The programme will initially focus on using AM techniques to create near-net shape parts that require minimal subsequent machining. This will "dramatically improve the 'buy-to-fly' ratio of the parts" by reducing material wastage and time associated with the conventional machining of metal forgings or billets. With material wastage as high as 90% for some parts, a significant reduction here will also provide major environmental benefits. CADCAM specialist Delcam will work with GKN Aerospace on an integrated solution to combine additive and subtractive technologies seamlessly. This will allow companies to benefit from both the geometric freedom offered by AM and the surface finish and accuracy that is possible with subtractive manufacturing. Renishaw is a designer and maker of metal additive manufacturing equipment. Rich Oldfield, technical director of GKN Aerospace, explains: "AM incorporates a range of hugely promising manufacturing technologies that the UK aerospace sector must fully understand and exploit, if it is to retain its position as the largest national aerospace industry outside the USA. This strong consortium has the expertise and understanding to continue the process of industrialising these technologies for use in both current programme updates and next-generation aircraft."