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FLOW Control Actuators at Aircraft scale manufacturing by SLM with high aerodynamic performance for using in Harsh environment

European Union
Geo-spatial type
Total project cost
€549 061
EU Contribution
€549 061
Project website
Project Acronym
STRIA Roadmaps
Vehicle design and manufacturing (VDM)
Transport mode
Airborne icon
Transport policies
Other specified
Transport sectors
Passenger transport,
Freight transport


Call for proposal
Link to CORDIS

The main goal of FLOWCAASH project is to design and manufacture reliable and safe flow control actuators at aircraft scale by Selective Laser Melting (SLM) able to withstand the high temperatures (up to 260 °C) and pressures (5 bar) during flight test with aerodynamic performance and high resistance to harsh environments. FLOWCAASH project is focused on the development of innovative designs of Active Flow Control (AFC) actuators to be manufactured by powder bed based additive manufacturing (AM) using Ti6Al4V alloy. Selective Laser Melting (SLM), that utilizes a laser as a thermal energy source to melt the powder has been chosen as the preferred AM technology. The innovative designs of these AFC actuators will allow to be installed in restricted space in the next generation aircrafts with UHBR (Ultra High Bypass Ratio) engines.

Two different actuators will be considered, Pulsed Jet Actuator (PJA) and Steady Blowing Actuator (SBA). These actuators will have the potential to reduce aerodynamic flow separation and to increase lift coefficient. This will be obtained by bionic design which allows complex geometries and improve structural strength while reducing the weight. In order to assure process reliability of large Ti parts, distortion prediction numerical simulations will be accomplished. As-built part will be post-processed by means of heat and surface treatments in order to ensure dimensional stability and adequate surface quality for aerodynamic performance.

Afterwards the actuators will be validated by aerodynamic and harsh environment tests including rain, icing, sand and dust, vibrations and anti-icing fluid. The FLOWCAASH project will be developed by a well-balanced consortium that brings together 2 partners: the research centre LORTEK and the aerospace test laboratory CTA.


Parent Programmes
Institution Type
Public institution
Institution Name
European Commission
Type of funding
Public (EU)
Specific funding programme
Other Programme
JTI-CS2-2017-CFP06-LPA-01-34 3D printing and harsh environment testing of flow control actuators at aircraft scale


Lead Organisation
Lortek S Coop
Arranomendia Kalea 4 A, 20240 Ordizia, Spain
EU Contribution
€348 811
Partner Organisations
Fundacion Centro De Tecnologias Aeronauticas
Parque Tecnologico De Alava (Minano), C/ Juan De La Cierva 1, 1510 Minano (Alava), Spain
Organisation website
EU Contribution
€200 250


Technology Theme
Additive manufacturing
Selective Laser Melting (SLM)

The utilisation of a laser as a thermal energy source to melt the powder has been chosen as the preferred additive manufacturing technology for aircraft applications.

Development phase
Demonstration/prototyping/Pilot Production

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