Additive manufacturing process design for complex aircraft components

Abstract The process of metal additive manufacturing (AM) is now widely used in fabricating complex parts today’s industry. scope this paper to redesign a for aircraft components using wing ribs as example by considering embedded Internet Things (IoT) sensory capability that can be an Industry 4.0 ecosystem moving away from condition-based preventive maintenance system data-driven predictive maintenance-based system. This work based on previous study considered the part design stage which deals with finding best solution single part. Considering rib geometry 3-mm web thickness 6-mm upper and lower caps, designed assessed Simufact Additive™ software. use AM when embedding IoT sensors allows more flexibility without compromising structural integrity parts, well advantage freedom limited cost modifying geometries. outcomes show depends strongly hot isostatic pressing (HIP) rib, but covers it presented no significant improvement. results also support optimisation lead important reduction mass volume improvement performance.