Aeronautical progression: Exploration of 3D Printing with PMMA and Casting Methods for Aviation Usage

TITAL GmbH, a German company specializing in investment basics, is making significant strides in the aerospace industry by producing high-quality aluminum and titanium castings. The company, which is part of the US Howmet Aerospace group, is renowned for its production of complex, installation-ready castings for various industries, including aerospace, defense, electronics, optics, racing, mechanical engineering, and medical technology.

One of TITAL's notable contributions to the aerospace sector is the manufacture of the hinge arm for the Chinese passenger aircraft Comac C919. Through topology optimization, TITAL was able to significantly reduce the weight of the hinge arm, previously heavy, by 47 percent. Rainer Sabisch, Director Global Application Engineering at TITAL, explains that weight reduction is crucial for high payload capacity in aircraft.

Another part produced by TITAL is the channel fitting, which is located in the landing gear shaft of the main landing gear and houses the hydraulic cylinder responsible for opening and closing the landing gear door. The company's channel fitting can be found in the Airbus A400M's landing gear, a transport aircraft with a high payload capacity. TITAL was able to reduce the weight of the channel fitting by 17 percent through topology optimization.

The A400M's channel fitting is one of the many parts produced by TITAL that benefits from 3D printing-based investment basics. This efficient tool offers topology optimization, precision, weight savings, and design freedom. In addition to the lost wax process from its partner voxeljet AG, TITAL uses 3D-printed PMMA patterns for investment basics.

The use of investment basics offers more efficient material use and higher recyclability, as shown in a public study by the German Federal Environment Agency. Compared to conventional production from a single bar, investment castings provide a more sustainable approach, reducing waste and promoting a greener aerospace industry.

TITAL's focus on weight reduction extends to its choice of materials. The aluminum alloy A205, for instance, can support and partially replace titanium alloys due to its increased strength and operating temperature, enabling weight savings of around 40 percent. Similarly, the titanium alloy THOR can operate at temperatures of up to 650°C, allowing for the partial replacement of superalloys (nickel-based alloys) and a weight reduction of around 50 percent.

More than 90 percent of TITAL's customers are in the aerospace industry, including Airbus, Boeing, and Safran Aircraft Engines. The company's commitment to innovation, sustainability, and quality has earned it a reputation as a trusted partner in the aerospace sector.

Despite the significant advancements TITAL has made, the company that manufactures the 3D-printed PMMA patterns for TITAL's investment basics foundry in Bestwig, Germany, remains unmentioned in the provided search results. Regardless, TITAL continues to push the boundaries of what is possible in the aerospace industry, driving innovation and efficiency through its use of advanced technologies and materials.