CASE STUDY - ADVANCED INNOVATIVE ENGINEERING
Advanced Innovative Engineering approached the Precision Manufacturing Centre, who were exhibiting at an Aerospace UP event in the autumn of 2021. They detailed the manufacturing challenges they were experiencing with the development of their new 3D metal printed components.
AIE ENGINEERING
Founded in 2012, AIE is an engineering company specialising in developing innovative rotary engines for a wide range of applications but with a central focus on unmanned vehicles. From its headquarters in Lichfield, UK, it manages entire project life cycles through concept, prototype and production. Working with international partners and customers, AIE creates technologies that combine low total cost-of-ownership (TCO) with exceptional reliability and versatility for global commercial and defence markets.
3D PRINTED COMPONENTS
AIE were facing challenges developing their new 3D metal printed components. The components were printed from aluminium alloy or maraging steel and were highly complex in design. When integrated together they formed part of a working assembly. The surface finish and accuracy of the printed components did not achieve the required functional requirements and so AIE approached the PMC for assistance finishing the components to create a surface roughness of less than 1 Ra on mating faces.
HIGH ACCURACY REQUIREMENTS
AIE provided the printed parts and technical drawings to the PMC, stating required dimensions and tolerances of the finished components. The tolerances the PMC machined achieved was sub 10 micron.
Four different parts were required, with a quantity of two per part, highlighting the capabilities of the PMC to manufacture in low volumes. Bespoke fixturing and tooling was developed as part of this project to ensure we could meet the accuracy and tolerance requirements of AIE.
COMPLEX MACHINING
The machining of the parts was highly complex and utilised a “3 + 2” machining methodology to ensure the accuracy of the manufacturing process. We used the Hermle C20U 5 axis machining centre to complete the manufacturing. Maintaining the high accuracy requirements was key to the delivery of this project.
Once the machining was completed, all components were verified against the technical drawings provided by AIE Engineering using our Zeiss O-Inspect coordinate measurement machine (CMM).
Working with the team at the PMC as part of the Aerospace UP project has enabled AIE to explore the specific design needs and requirements of component design when machining additive manufactured components. The PMC’s team’s core expertise and experience has enabled AIE to not only truly understand the massive potential for this technology in our engines’ design but also at the same time the limitations that need to be considered regarding tolerancing and material allowance to achieve high-quality, high-precision components.
Nathan Bailey, Managing Director, Advanced Innovative Engineering (UK) Ltd.