• March 1, 2021
  • Register
  • Sign in
    • Forgot Password ?
    OR
    • Sign in
  • FAQ
  • Contact
  • About us
www.cnctimes.com logo
  • Editorials
    • NEWS
    • CASE STUDIES
    • INTERVIEWS
    • SUCCESS STORY
    • PRODUCT SHOWCASE
    • TECHNICAL ARTICLES
    • BLOGS
    • VIDEOS
    • NEWSLETTERS
  • Forum
  • EVENTS
  • INVENTORY
    • INVENTORY LISTINGS
    • AUCTION LISTINGS
    • WANTED LISTINGS
  • BUSINESS LEADS
    • BUYERS
    • MANUFACTURERS
    • DEALERS
  • SHOWROOM
  • JOBS
  • Register
  • Sign in
  • Contact
  • Advertise
  • Feedback

Information

Please login to give the feedback.

Information

Please login to give the feedback.

  1. Home
  2. Case Studies
  3. Aerospace: Sogeti - Additive Manufacturing for the new A350 XWB

Aerospace: Sogeti - Additive Manufacturing for the new A350 XWB

29 March, 2019
  • Tweet
  • share via email
Your comment has been posted.
We have sent you a verification email. To verify, just follow the link in the message.
Some technical error. Please try again.

A350 XWB cable routing – from design to component in two weeks

The moment when a completely new commercial aircraft takes to the skies for the first time is always special – and this was especially true of the Airbus A350 XWB. As a child of the new millennium, it was clear from the very beginning that development work would focus on innovative materials and production processes – the goal was no less than to build the world's most efficient aircraft. As a technology of the future, additive manufacturing was another possibility that needed to be considered during development. As part of a pilot project, experts from Sogeti High Tech succeeded in developing a cable mount on the front spar of the vertical stabilizer for the passenger aircraft in record time, taking only two weeks from the initial sketch to the finished part. EOS technology and expertise was a pivotal aspect of this development process.

Challenge

The project specifically involved producing a cable routing mount for the latest Airbus model. The mount was ultimately needed for the power supply and data transportation of a camera located in the vertical stabilizer, providing a view of the outside to passengers and orientation on the ground to the pilots. The product requirements document called for a functionally operational component suitable for series production. This task was entrusted to Sogeti High Tech, a wholly-owned subsidiary of Cap Gemini S.A., which is listed on the Paris stock exchange.

The particular challenge, in this case, was the short lead time of just two weeks. The entire development had to be completed within this time frame: From the analysis of the part and of the current installation set-up, a parameter study aimed at optimizing the topology and its interpretation, and the design and production of the finished part. The mount also needed to have a few support structures as possible to avoid post-processing. In addition, the specifications for the component called for the integration of the snap-on cable holder, weight reduction, and compliance with the strict requirements for subsequent aviation industry certification.

The conventionally produced component was made up of formed sheet metal parts and numerous rivets – more than 30 individual parts in total. The plug connectors in the upper area were made from plastic, and thus from a different material than the other individual parts of the mount. The aim was to develop an integrated solution consisting of a single part that also included the plug connectors, thereby significantly reducing construction and installation times. The weight reduction target for additive manufacturing was determined by a parameter study based on topology optimization.

Solution

For the new component, Sogeti High Tech followed the tried-and-tested development process for designing additively manufactured parts. The project kicked off with an analysis of the existing, conventionally produced component in terms of the upcoming manufacturing process – with an extremely positive outcome. The component's functionality, material, and previously complex structure made it an ideal candidate for powder-bed-based 3D printing technology from EOS. The design freedom offered by this technology allows complex structures to be produced in a single piece, meaning that a weight-saving design can be selected without neglecting functional integration.

This analysis then allowed the so-called design space – the space that the cable-routing mount may occupy – to be defined. The aluminum alloy AlSi10Mg, which is ideal for thin-walled, complex structures, was chosen as the material. The interfaces to the external areas remained the same, forming the non-design space, meaning that no changes needed to be made to them. The defined loads were taken as the boundary conditions for topology optimization in the parameter study, providing the basis for a new design.

As is customary, CAE software was used for the topology optimization calculations; in, by contrast, a dedicated solution for designing structures with free-form surfaces was used for the re-design. Sogeti High Tech created the design itself. In order to meet the lead time of two weeks, EOS calculated the build time and optimized parameters from the topology optimization results using the software EOSPRINT. This created the CAE implementation for the manufactured part while also taking into account the possibilities and limitations of the manufacturing process and the need to avoid support structures. “In addition to outstanding hardware, EOS also offers comprehensive expertise in making additively manufactured components reality – something that we rate very highly," says Carlos Ribeiro Simoes, Additive Manufacturing Offering Leader at Sogeti High Tech.

Results

Thanks to the cooperation between Sogeti and EOS, it was possible to develop a component optimized for additive manufacturing that fully exploits the design freedom afforded by DMLS technology while at the same time taking account of its restrictions. This allowed plug connectors for cable routing to be integrated into the design and local reinforcement to be incorporated in specific critical areas in order to optimize the structure. Self-supporting apertures and struts within the component help to keep the effort and hence the post-processing costs to a minimum.

Additionally, the mount can be produced extremely fast, whenever it is needed. Manufacturing – which is performed on an EOS M 400 with layer thicknesses of 90μm – only takes 19 hours instead of the 70 days previously required. This corresponds to a reduction in the production time well in excess of 90 %. This is largely because the many individual steps and formerly 30 parts have been brought together in a central component that can now be produced in a single run. In addition, the individual parts no longer need to be constructed and held in stock, which can be expensive. Storage for the entire component assembly is now also much more straightforward.

Sogeti was not only able to save a huge amount of time in production, but also in development. The entire process from the initial sketch to the finished component took only two weeks. This is a phenomenal lead time. At the same time, the design also means greater weight efficiency. Whereas the conventionally manufactured original part weighed 452 grams, the additively manufactured cable mount weighs just 317 grams – and it is well known that the aviation industry counts every single gram in the interest of cutting fuel consumption to a minimum. The customer, Airbus, was more than satisfied with the results.

“Getting an existing component 'AM-ready' in just two weeks meant that we had to succeed at the first attempt. The excellent, proactive collaboration with EOS made this ambitious undertaking possible – with outstanding results."
Carlos Ribeiro Simoes, Additive Manufacturing Offering Leader at Sogeti High Tech
 
Brief profile
 
Sogeti High Tech is a wholly-owned subsidiary of Cap Gemini S.A. and the group's center of excellence for systems engineering physical engineering, and software engineering, as well as testing and consulting. Sogeti supports customers in their basic groundwork and in systematically training and qualifying employees for additive manufacturing. It offers the complete spectrum of AM services in collaboration with EOS.
  • Follow @CNCTimes

Captcha is required.
Sorry Captcha Unsuccessful!!

Latest Case Studies

  • 03 August, 2020

    Automated production line for FFP3 filters up and running after just eleven days with the help of SCHUNK

  • 07 January, 2020

    In-house metrology increases machine tool uptime by 20%

  • 16 December, 2019

    Lifting Devices Provider Cyrus Designs 20% Faster with ZW3D

  • 16 December, 2019

    Khodiyar Industries Chose ZW3D to Speed up Packaging Machine Production

  • 16 December, 2019

    In-house metrology increases machine tool uptime by 20%

  • 19 August, 2019

    Automated workpiece set-up boosts forestry equipment manufacture

  • 30 July, 2019

    Laser interferometer error-proofs linear scale calibration

  • 08 July, 2019

    Improving speed and reducing cost with Renishaw additive manufacturing

  • 04 June, 2019

    Venturing into metal additive manufacturing

  • 13 May, 2019

    Renishaw Equator™ gauge enables production growth at major aerospace manufacturer

  • 08 April, 2019

    50% faster turbine blade inspection

  • 08 April, 2019

    FARO® QuantumS ScanArm: Executing the Work of Two Measurement Devices

  • 04 April, 2019

    Laser interferometry assures spherical lens quality

  • 01 April, 2019

    Why The World's Third Largest Motorcycle Manufacturer Opted For Universal Robots

  • 28 March, 2019

    Overcome the Ongoing Challenges of Long-Reach Machining

  • 12 March, 2019

    BLUM touch probes on Strama-MPS

  • 11 March, 2019

    INTECH DMLS Achieves 27% Weight Reduction in 3D Printed Satellite Component using Altair InspireTM and OptiStructTM

  • 14 February, 2019

    Zoom Technologies Chooses CADbro, a powerful 3D CAD Viewer, to Accelerate Customized Mold Production

  • 25 December, 2018

    Renishaw and Hartford combine to deliver intelligent, ‘smart factory’ solutions

  • 18 December, 2018

    Measurement of free-form surfaces made easy

  • 14 December, 2018

    A Measuring Tool System That Modified the Concept of Machinery

Previous Next

Related Case Studies

  • 10 April, 2018

    Capacity Ahead Of Demand Is Going To Be The Driving Factor For Growth: General Machine Tools

    Category: Machine Tools
  • 10 April, 2018

    Customer Support is Very Crucial for The Success: Padmavati Group

    Category: Machine Tools
  • 03 April, 2018

    HAAS moulds the future for Mechasoft through Reliability and Flexibility

    Category: Machine Tools
  • 22 March, 2018

    HAAS - Enabling Leonine Deliver Highly Precise, Highly Accurate, High Volume Components

    Category: Machine Tools
  • 20 December, 2017

    Renishaw AM technology helps Swinburne electric car to best-ever Formula SAE result

    Category: Machine Tools
  • 07 August, 2017

    Exchanging metal 3D printing solutions with HiETA

    Category: Machine Tools
  • 29 June, 2017

    KOMET® GROUP innovates cutting tools using metal 3D printing technology

    Category: Machine Tools
  • 29 June, 2017

    Hermle machines are reliable and helps maintain the desired accuracy: Seco Tools , Case Study

    Category: Machine Tools

News

  • 26 February, 2021

    Phillips Machine Tools boosts its strong additive manufacturing portfolio with the addition of the Markforged Digital Forge

    Category: Machine Tools
  • 23 February, 2021

    Mr. D M Sheregar of Devu Tools Elected as New President of TAGMA India

    Category: Machine Tools
  • 23 February, 2021

    New GROB 5-Axis Machine Helps Machining Experts Improve Production Quality, Complexity, and Speed

    Category: Machine Tools
  • 15 February, 2021

    Divide By Zero secures US patent for AFPM technology for 3D printing

    Category: Machine Tools
  • 09 February, 2021

    e-Xstream engineering enables manufacturers to weigh up the production cost of composite 3D printing

    Category: Machine Tools
  • 01 February, 2021

    Truventor.ai joins hand with TAGMA for a webinar on on-demand-manufacturing

    Category: Machine Tools
  • 25 January, 2021

    Laser solution with two different wavelengths

    Category: Machine Tools
  • 25 January, 2021

    HURCO INTRODUCES NEW DRIVEN TOOL LATHES

    Category: Machine Tools
  • 22 January, 2021

    Launch of VX 6500G and VX 6500C, Vertical Machining Centers for High-precision Graphite and Ceramic Processing

    Category: Machine Tools
  • 18 January, 2021

    TRUMPF Venture invests in two AI/ML-powered cyber security start-ups

    Category: Machine Tools
  • 25 January, 2021

    GROB G550T Meets Demanding Manufacturing Needs of Simmons Machine Tool Corporation

    Category: Machine Tools
  • 18 January, 2021

    POWER SKIVING HIGH QUALITY, PRODUCTIVITY AND COST EFFICIENCY IN GEAR CUTTING

    Category: Machine Tools

Interviews

  • 30 April, 2019

    CNCTimes in conversation with, Ankit Sahu, Director, Objectify Technologies Pvt. Ltd.

    Category: Machine Tools
  • 10 July, 2018

    Niraj Wanikar, M.D., CNCTimes P. Ltd. talks about Plant Manager – a revolutionary Production, Planning and Control software.

    Category: Machine Tools
  • 10 July, 2018

    Mr Cyril Pereira, MD, Reed Triune Exhibitions, talks about AMTEX 2018

    Category: Machine Tools
  • 10 July, 2018

    Mr. Benedikt Ruf, MD, GINDUMAC GmbH and Mr. Pankaj Patel, Country Manager, GINDUMAC GmbH share their views about AMTEX 2018 and the Indian Market

    Category: Machine Tools
  • 10 July, 2018

    HMB International is getting overwhelming response at AMTEX 2018: Mr Gopal Bali, Country Manager Sales, HMB International

    Category: Machine Tools
  • 10 July, 2018

    SLTL is a global leader in CNC laser services: Mr Maulik Patel, Business Development - International, SLTL Group

    Category: Machine Tools
  • 21 June, 2018

    Indian customers shower trust on HAAS, and Phillips has perpetually strived to make this a reality.

    Category: Machine Tools
  • 18 December, 2017

    “Engimach helps you to reach the right audience.”:Macpower CNC

    Category: Machine Tools
  • 11 December, 2017

    ‘Engimach is the best platform to showcase your products’ : Gravotech

    Category: Machine Tools
  • 23 February, 2017

    Nicolas Correa is Expanding Presence in India by Providing Complete Solutions:Jose Nicolas Correa

    Category: Machine Tools
  • 31 January, 2017

    Indian market is very interesting and important for GROB: Alexander Attenberger

    Category: Machine Tools
  • 29 January, 2017

    LMW always adds values to its system: K Soundhar Rajhan

    Category: Machine Tools

Product Showcase

  • 04 February, 2020

    HYPERTURN 65 Powermill – For Increased Productivity in Complex Complete Machining

    Category: Machine Tools
  • 08 December, 2019

    Electronica HiTech brings Latest Technology in CNC Wire CUT EDM- Model Job Master D zire

    Category: Machine Tools
  • 08 December, 2019

    Electronica HiTech brings CNC Vertical Machining Center MVP Series (Linear Guide Way) from Hartford

    Category: Machine Tools
  • 08 December, 2019

    Electronica HiTech offers you high speed, High Accuracy, Precision Machining Centers- TGV series from Hartford

    Category: Machine Tools
  • 08 December, 2019

    Electronica HiTech brings Centerless GrinderMachine- JHC 18 From Jainnher

    Category: Machine Tools
  • 08 December, 2019

    Electronica HiTech brings High-Rigidity & Heavy-Duty Cutting Horizontal Turning Center from Doosan Machine Tools

    Category: Machine Tools
  • 07 December, 2019

    Electronica HiTech brings High Productivity Gang type Global Compact Turning Center from Doosan Machine Tools

    Category: Machine Tools
  • 07 December, 2019

    ELTECH-D400 ZNC EDM from Electronica HiTech Machine Tool Pvt. Ltd

    Category: Machine Tools
  • 07 December, 2019

    Electronica HiTech deals with VMC that guarantees unmatched performance

    Category: Machine Tools
  • 06 December, 2019

    CNC Precision Grinding Machine from Tsugami G300/G350

    Category: Machine Tools
  • 06 December, 2019

    VA3 High Speed Vertical machining Center from Tsugami

    Category: Machine Tools
  • 06 December, 2019

    Electronica HiTech brings High Precision Surface Grinder from Proth Industrial Co.,Ltd

    Category: Machine Tools

Technical Articles

  • 28 January, 2020

    The Additive Update: Wilson Tools

    Category: Machine Tools
  • 04 May, 2019

    Faster and better machining performance: on existing equipment

    Category: Machine Tools
  • 23 April, 2019

    The 3D FABRI GEAR Advantage

    Category: Machine Tools
  • 19 April, 2019

    Development of Two Types of Sintering Bonding Materials for Next-generation Power Modules

    Category: Machine Tools
  • 22 March, 2019

    THE PRECISE GEOMETRY OF 3D CUTTING KBM motors as a byword for accuracy in laser cutting

    Category: Machine Tools
  • 05 March, 2019

    Fire risks in a CNC

    Category: Machine Tools
  • 19 February, 2019

    Group Technology: Operational Excellence in the Industry 4.0 Era

    Category: Machine Tools
  • 13 June, 2017

    PRACTICAL APPROACH TO CONTROL WASTE IN MANUFACTURING

    Category: Machine Tools
  • 20 March, 2017

    PiWeb from Zeiss Metrology:  Quality Data Management with Easy Reporting

    Category: Machine Tools
  • 28 December, 2016

    Chamfering and Deburring gears precisely to achieve smoother gear transmissions

    Category: Machine Tools
  • 14 December, 2016

    New milestones in microfinishing--Precision engineered finish for auto parts

    Category: Machine Tools
  • 28 November, 2016

    Robotic deflashing for aluminium die castings: A revolution in alu-cast industry

    Category: Machine Tools

Blogs

  • 19 April, 2019

    Additive Manufacturing: a big leap in production

    Category: Machine Tools
  • 14 August, 2017

    Industry 4.0 applications outside

    Category: Machine Tools
  • 01 August, 2017

    Industry 4.0: Applications in a shop

    Category: Machine Tools
  • 19 July, 2017

    Industry 4.0 – Machine monitoring

    Category: Machine Tools
  • 24 May, 2017

    Achieving tolerance less than the accuracy: CNC

    Category: Machine Tools
  • 17 May, 2017

    Key parts of a CNC fixture

    Category: Machine Tools
  • 09 May, 2017

    Mohs scale and cutting tools

    Category: Machine Tools
  • 10 April, 2017

    Epoxy granite beds in CNCs

    Category: Machine Tools
  • 25 March, 2017

    Industry 4.0 demystified

    Category: Machine Tools
  • 17 February, 2017

    The CNC teaching gap in the industry

    Category: Machine Tools
  • 02 December, 2016

    Exact stop check in Milling

    Category: Machine Tools
  • 26 October, 2016

    How to purchase used high-quality injection molding equipment

    Category: Machine Tools

Videos

  • 24th February, 2021

    Machine tools: A Virtual representation

    Category: Machine Tools
  • 21st July, 2020

    Offline Programming For Press Brakes & Full 3D Simulation For Sheet Metal Bending

    Category: Machine Tools
  • 20th July, 2020

    Bill of Materials in WORKPLAN

    Category: Machine Tools
  • 07th July, 2020

    Sales order creation in WORKPLAN

    Category: Machine Tools
  • 07th July, 2020

    Online Event Teaser | Die & Mould - Make it Smarter!

    Category: Machine Tools
  • 01st July, 2020

    DESIGNER: Direct Modelling CAD software.

    Category: Machine Tools
  • 04th May, 2020

    CAM Software 3D Mold Part SolidCAM iMachining

    Category: Machine Tools
  • 04th May, 2020

    SolidCAM Car wheels CNC Machining 5 Axis

    Category: Machine Tools
  • 04th May, 2020

    SolidCAM Mill Turn & iMachining on OKUMA Multus BII series

    Category: Machine Tools
  • 04th May, 2020

    SolidCAM Advanced Mill Turn on a Citizen D25 CNC with Iscar

    Category: Machine Tools
  • 30th April, 2020

    5 axis laser cutting process by Radmax

    Category: Machine Tools
  • 21st April, 2020

    Check out how easily you can create the quotation in WORKPLAN for existing opportunity.

    Category: Machine Tools

Inventory

  • 17 July, 2019

    2001 MORI SEIKI ZT2500Y 4-AXIS TWIN SPINDLE TWIN TURRET CNC LATHE W/ LIVE MILLING AND BAR FEED

    Category: Machine Tools
  • 17 July, 2019

    2010 OKUMA B-300W CNC Lathes

    Category: Machine Tools
  • 17 July, 2019

    2004 Gildemeister Twin 42 CNC Lathe with Siemens Control

    Category: Machine Tools
  • 17 July, 2019

    2005 DOOSAN/DAEWOO PUMA 2500 LSY MULTI AXIS MILL & TURN CENTER/LATHE

    Category: Machine Tools
  • 17 July, 2019

    2013 MORI SEIKI NMV5000 DCG 5-Axis CNC Vertical Machining Center

    Category: Machine Tools
  • 17 July, 2019

    2000 WALDRICH COBURG MULTITEC 2500 AP CNC PORTAL MACHINING CENTER

    Category: Machine Tools
  • 17 July, 2019

    2005 MORI SEIKI MT 2500SZ/1500 TWIN SPINDLE CNC MILLING / TURNING CENTER

    Category: Machine Tools
  • 17 July, 2019

    2013 Mazak Integrex e-670H II 4000U 5-Axis Multi-Tasking CNC Turning & Milling Center

    Category: Machine Tools
  • 17 July, 2019

    2006 MAZAK Integrex IG 300 IV ST CNC Turning/Milling Center

    Category: Machine Tools
  • 17 July, 2019

    2009 HAAS SL-20T CNC 2-AXIS TURNING CENTER LATHE W/EPSON 6-AXIS MATERIAL HANDLING ROBOT

    Category: Machine Tools
  • 17 July, 2019

    2014 DMG NT6600 DCG CS X 6000 Turning Milling Centre.

    Category: Machine Tools
  • 17 July, 2019

    2008 MORI SEIKI NT4200/1000SZ DCG 5-AXIS CNC MILLING AND TURNING CENTER W/ GANTRY LOADER

    Category: Machine Tools

Showroom

  • 31 March, 2020

    MJP 2500-IC

    Category: Machine Tools
  • 09 October, 2019

    joanna Wong

    Category: Machine Tools
  • 28 November, 2018

    Polycarbonate Roof Sheet Manufacturers

    Category: Machine Tools
  • 28 November, 2018

    Industrial Exhaust Fans Manufacturers

    Category: Machine Tools
  • 17 November, 2018

    DMU -50 DMG GERMANY

    Category: Machine Tools
  • 17 May, 2018

    201

    Category: Machine Tools
  • 22 December, 2017

    Ul-

    Category: Machine Tools
  • 06 May, 2017

    LSV-2050

    Category: Machine Tools
  • 06 May, 2017

    GST - 55 TO LST - 525

    Category: Machine Tools
  • 08 April, 2017

    tecnicrafts

    Category: Machine Tools
  • 08 April, 2017

    Nakanishi

    Category: Machine Tools
  • 08 April, 2017

    PCM Willen S. A.

    Category: Machine Tools

TESTIMONIALS VIEW MORE

We would like to express our sincere appreciation for your service to us.You have provided us best marketing platform through CNCTimes. We look forward to extending our contract with you for years to ...

Mr.Adil Atar, Ass.Mng.Technical Sales & Service: Precision Machinekraft

Dedication and determination is key to success and CNC Times team is evident to it - FARO Business Technologies (I) Pvt Ltd

Ms. Amrita Gokhale , FARO Business Technologies

Seminar was really very good, please let us know about future seminars. we would like to attend the seminar on "Machining of the material above 60 HRc like titanum"

Roshan Deshmukh, Design Engineer - Ashvini Magnets Private Limited

FOLLOW US

TECHNOLOGY FOCUS

    Machine Tools

    • CNC Lathe
    • Boring Machines
    • Drilling Machines
    • Spark Erosion
    • Wire Cut
    • Vertical Machining Centers - VMC
    • Horizontal Machining Centers - HMC
    • Grinding Machines
    • Gear Cutting Machines
    • Additive Manufacturing - RP
    • Multi-Axis Machines
    • Multi-Tasking Machines
    • Welding Machines
    • Presses
    • Laser Cutting
    • Others
    • IIoT

    Metrology

    • CMM
    • VMM ( Vision Measuring Machines )
    • PCMM ( Portable CMM )
    • Measuring Instruments
    • Probing Technology
    • 3D Scanners
    • Roundness Measurement
    • Surface Roughness Measurement
    • Contour Measuring Machines
    • Others

    Accessories

    • Workholding
    • Toolholders
    • Spindles
    • Coolants
    • Others

    Software

    • CAD
    • CAM
    • CAE
    • ERP
    • Inspection Software
    • Reverse Engineering Software
    • MES
    • Others

    Mechatronics

    • Robotics
    • Automation
    • CNC Controllers
    • Others

    Cutting Tools

    • Turning Tools
    • Milling Tools
    • Grinding Wheels
    • Drilling
    • Others

INDUSTRY VERTICALS

  • General
  • Automotive
  • Aerospace
  • Healthcare
  • Healthcare Engineering
  • FMCG
  • Consumer Durable
  • Defence
  • Electronics
  • Oil & Gas
  • Heritage
  • Heavy Engineering
  • Die & Mold
  • Plastic
  • Footwear
  • Jobshop

POLICIES

  • Payment Policy
  • Terms of Use

PROFILE

  • About us
© 2021 www.cnctimes.com
Developed & Maintained by CNCTimes.com