Overview
Aim of the RepAIR project is to perform research on future repair and maintenance for the Aerospace industry. Therefore, the onsite maintenance and repair of aircrafts by means of integrated direct digital manufacturing is in the focus of this project. The main objective of RepAIR is to shift the 'make' or 'buy' decision towards the 'make' decision by cost reduction in the remake and rework of spare parts and so to improve cost efficiency for maintenance repair in aeronautics and air transport. A crucial advantage of this technology is the flexible availableness (even at the gate) allowing on-time maintenance. New business models will become sustainable. Through a higher automation level and fewer stages of production, less personal costs will be necessary which will reduce the MRO costs. These operations require a higher qualification and promote the preservation and expansion of highly qualified workplaces in Europe and will make them more competitive. Moreover, the storage costs will be significantly reduced. As only the raw material needs to be stored, instead of having to have in stock up to 3.6 million spare parts for the multitude of airplanes and variety of aircraft manufacturers, less capital is locked up. Additionally, hardly any energy-intensive produced raw material will be wasted or destroyed, but will be used optimally. When looking ahead, with the aid of AM technology, it will be possible to shorten the entire spare parts supply chain to sending an e-mail. The benefit for all those involved, including the environment, is obvious.
Funding
Results
On-site spare part production for aircraft
Additive manufacturing (AM), or 3D printing, is a rapid process for building up a part of complex geometry with minimal material waste. Innovative application of AM to on-site aircraft maintenance and repair is preparing for take-off.
AM, which sequentially adds layers of material according to specifications in a computer-aided design file, has progressed tremendously since its inception for small batches of custom-designed parts. Its application to the maintenance, repair and overhaul (MRO) process in the aerospace industry is a promising way to cut costs, downtime and scrap. The EU is supporting development efforts and activities carried out in the project 'Future repair and maintenance for aerospace industry' (http://www.rep-air.eu/ (REPAIR)).
With only raw material stored rather than millions of spare parts, less capital is locked up and potentially wasted. The energy consumption associated with production of all those spare parts is eliminated. Scientists plan to demonstrate the benefits of making new parts rather than buying them to improve the cost efficiency of MRO processes in aeronautics and air transport.
Within the first project period, the team defined the information technology (IT) management platform and the planned production system. The team has established a classification system for AM particular to aerospace parts that will aid in suggesting the best repair options. A basic structure for the certification part of the IT programme has been developed.
Project partners evaluated their manufacturing processes and identified the main cost drivers to be included in the decision support tool. Importantly, the consortium identified four future scenarios to include indicators related to the likely evolution of AM to ensure the decision support tool will remain relevant.
Scientists have selected sample parts and developed the test rig. A clamping device and in situ control system are under development as is software to integrate the laser cladding process.
REPAIR technology promises numerous benefits, including a significant reduction in MRO costs and time, job creation, reduction of scrap and energy consumption, and enhanced aircraft safety. Innovative application of AM to on-site maintenance and repair is an idea ready to take flight.