Subscribe Now
APPLICATIONAVIATION

Honeywell Secures FAA Approval for 3D Printed Flight-critical Part

2 Mins read

3D printed flight-critical part (the bearing housing) paves the way for future certifications, solves critical supply chain shortages for complex engine parts

3D printed flight-critical

Above: Dassault Falcon 20G maritime patrol aircraft/Image Credit: Dassault Avation


Honeywell, a multinational conglomerate operating in multiple business areas including aerospace, revealed that it has received its first FAA approval for a 3D printed flight-critical engine part.

The part, the #4/5 bearing housing, is a structural component for the ATF3-6 turbofan that powers the Dassault Falcon 20G maritime patrol aircraft operated by the French Navy. The ATF3-6 engine was certified in 1967, and only about a dozen are still flying, making parts sourcing difficult.

Adding to the complexity of the matter, Honeywell mentioned that the production of the #4/5 bearing housing through traditional means is a complicated process, requiring expensive specialty tools and moulds. This drives up the cost of replacement, particularly given the low order quantities. Additive manufacturing, however, enables parts to be made more quickly and in smaller quantities, without the need for expensive tools. Honeywell’s process involves the use of a laser that fuses layers of powdered metal into the part form.

[penci_related_posts taxonomies=”undefined” title=”Related Posts” background=”” border=”Blue” thumbright=”yes” number=”4″ style=”grid” align=”none” displayby=”cat” orderby=”random”]

According to Jon Hobgood, VP of manufacturing engineering for Honeywell Aerospace, “Though there aren’t many in service, Honeywell is responsible for supporting and maintaining these engines. We had to find a way to address these supply-chain issues and keep these aircraft flying. We were able to use our expertise in additive manufacturing to produce the qualified part much faster, reducing our lead time from approximately two years to two weeks.”

Because the #4/5 bearing housing is considered “safety-critical” or “flight-critical” from a regulatory standpoint, it must always function properly and must be approved by regulatory organizations.

The FAA has expanded its regulatory and research efforts in the area of additive manufacturing and has worked with Honeywell on the development and certification of multiple components. Honeywell said this collaboration enabled the approval of the flight-critical component through delegated authority.

Hobgood added, “This is a major milestone for Honeywell because it demonstrates the maturity of our additive manufacturing operations and paves the way for us to print more certified flight-critical parts. It also is a major win for the additive industry, as flight-critical parts face heavy scrutiny and high standards for qualification and installation on aircraft, but this shows it can be done.”

 With the approval in hand, Honeywell is stepping up production of the housing, anticipating the completion of dozens by year-end.

Honeywell began exploring additive manufacturing in 2007 through its lab in Phoenix and has since produced hundreds of aircraft components. It has further expanded those efforts to operations in China, Europe, India, and the U.S.


About Manufactur3D Magazine: Manufactur3D is an online magazine on 3D Printing. Visit our Global News page for more updates on Global 3D Printing News. To stay up-to-date about the latest happenings in the 3D printing world, like us on Facebook or follow us on LinkedIn.

1742 posts

About author
Manufactur3D is an Indian Online 3D Printing Media Platform that reports on the latest news, insights and analysis from the Indian and the Global 3D Printing Industry.
Articles
Related posts
AVIATIONAPAC

New Chinese aircrafts are using 3D Printing technology for better performance

3 Mins read
Chinese aviation industry revealed that its new fighter aircrafts are using 3D printing technology as the technology provides significant advantages
AVIATION

AddUp and Dassault Aviation to use metal AM technology for aeronautics mass production

3 Mins read
AddUp Solutions and Dassault Aviation are working together to transition metal AM technology workshop for aeronautics for mass production.
AMERICAS

GKN Aerospace to establish a new Additive Manufacturing Center of Excellence in Texas

2 Mins read
GKN Aerospace has announced the relocation of its North America additive manufacturing centre of excellence to Fort Worth’s Lone Star center.