Deploying Additive Manufacturing

Thanks to multiple exclusive and certified applications, particularly in the “new space”, Additive Manufacturing proves product benefits, strategic possibilities and flexibility gains for the entire value chain. Manufacturing leaders in Aerospace & Defense seek then to extend additive manufacturing adoption across their enterprise, Organization, IT and industrialization teams are facing a major gap: AM delivered by small-dedicated teams, away from standard process, is not ready to scale. Digital continuity is broken; up to seven best of breed software can be used in a raw. Therefore, costs remains high: many  iterations, high scrap rates, long certification process, low volumes. Data analytics, machine learning and AI might be a solution but are hard to deploy in such a context. Actually, managers are suspicious, program leader’s stay quite reluctant, engineering departments are maintaining a status quo, volumes remains quite low. It’s hard to engage sub-contractors, suffering of a lack of visibility in front of massive investments. Finally, purchasers challenge traditional manufacturing providers, using AM as a scarecrow.

Question is not any more “why AM” but “how to deploy AM”

Dassault Systèmes has set a strategy and embraced this challenge: end-to-end digitally connected, science based. By leveraging the 3DEXPERIENCE® platform for AM, engineers can rapidly explore multiple optimized concept shapes that are optimized based on not only the part specifications but also constraints specific to the additive manufacturing process. Engineers also consider multi-material requirements (polymers, metals, and engineered materials) and specialized 3D printers to produce these optimized parts. And innovative aerospace companies ‘connect the dots’ by advancing the ability of teams across their enterprise to collaborate throughout the product development process in order to reap the full value that additive manufacturing has to offer.

Working in the same digital platform, manufacturers get roles for building. They have the ability to prepare and compute AM processes by validating the operation before printing. It provides an intuitive user experience by utilizing a simplified user interface that defines the workflow tailored to the type of printer selected thanks to partnership with machine builder’s leaders.

In some of our metal printing, previously there was a 50/50 chance of getting a successful print, even when we've set up the theoretical model & print correctly. When we started using simulation software from Dassault Systèmes our success rate increased to 80%. So, that is a big jump, because of simulation and because predictable accuracy now.

Jeswin Joseph
Program Manager | Associate Director , National Institute for Aviation Research, Wichita State University

This whitepaper is your Additive Manufacturing road map. It illustrates the critical need for purposeful digital continuity and organizational buy-in that are required to realize the benefits of Additive Manufacturing.