2024-09-26 07:06:00
At KLM Engineering & Maintenance Engine Services, 3D printing plays a crucial role in supporting operations by facilitating the development of various types of tooling. In a week’s time, the 3D printing team in KLM Makerspace sometimes consumes up to 10 kilograms of filament. By printing tooling, the airline shortens lead time and also saves costs. And that is very important in the aviation industry.
For the past six months, Alejandro van Meer has been working as a Repair Development Engineer at Air France KLM’s Makerspace at Schiphol. Here a combination of engineers and interns are working together with the mechanics to explore innovative technologies such as 3D printing, robotics, AI Vision. They regularly work together on projects, but each has their own focus area. For Alejandro van Meer, who completed his master’s degree in Management of Technology at TU Delft, that is 3D printing.
Purchasing of tools from the OEM is expensive and time-consuming due to lead times. Therefore, we 3D design tooling solutions and 3D print them
Tooling for MRO department
His main focus is now on 3D printing tooling for KLM Engineering & Maintenance Engine Services. “Purchasing of tools from the OEM is expensive and time-consuming due to lead times. Therefore, we 3D design tooling solutions in consultation with the employees on the shop floor. After we print the tooling, they test it is and experiment to determine what works and what doesn’t,” says Alejandro about how he works together with MRO-technicians. During AM for Production (Oct 2nd at Mikrocentrum) he will give a lecture about 3D printing for maintenance purposes at KLM. The examples are numerous. Such as covers for when the maintenance technicians have to shot peen certain engine parts. In the past, they had to mask the parts that were not allowed to be treated, with a special tape. Not only is this tape expensive, but most importantly masking is time-consuming. Alejandro van Meer: “Now we’re printing the cover. This means that our highly-skilled staff can perform the more complex tasks instead of taping a section of a part. Financially, this is very interesting because we save a lot of man-hours and the process is much more efficient.” If larger covers are required than the print size of the desktop 3D printers, they are printed in several parts and then join them.
Tools for dot peening
Another tool is used if the service technicians need to apply codes or markings to the fan blades. This is done by dot peening. Until recently, they had to take out the fan blades, take them to the workbench and secure it to prevent it from moving. Not only are the blades heavy, they are also expensive,” explains the KLM E&M engineer. In Makerspace, a tool has now been developed So that they can do it in a more convenient way.
Low threshold
KLM E&M uses Ultimaker and since shortly some Bambu Labs 3D printers. Mainly PLA, PetG and TPU are used as material. “Tooling doesn’t always require high surface quality or super fine details. These 3D printers are good enough for that,” explains Alejandro van Meer. The maintenance technicians can submit their own requests for the design and 3D printing of tooling. Everything is organized in such a way that it is easy for mechanics to ask for 3D printed tools. Sometimes special tools are needed, which are developed in consultation and require multiple iterations. Alejandro van Meer: “If the part we need to design is very complex, we utilize a combination of technologies, including laser line scanners, to create a highly detailed CAD model. This allows us to precisely design the tool around the part.”
Strong infills
Sometimes, because of the strength, you have to choose solutions that you normally don’t want with 3D printing, such as replacing infill with almost a full material. This is the case, for example, with the covers for shot peening. By printing 100% infill, they can be used multiple times. With other tooling, like cover plugs, it is important that they have a snug fit but that the technicians can remove them properly. Then PLA is combined with TPU. And the color is also important. Alejandro van Meer: “The tooling must be clearly visible to prevent us from forgetting to remove something.” That’s why a lot of red and orange is printed. Even though multiple checks are in place to ensure all tooling is removed, it is essential to make the tooling as evident as possible.
AM for Production starts with a AM Bootcamp by ASML, Hexagon, Additive Industries, K3D and other partners. Read this article to learn more about the AM Bootcamp
Immense potential
“3D printing holds immense potential, and what we are currently doing, is just scratching the surface of what is possible. I’m excited to see what the future holds for 3D printing at KLM.” says the KLM engineer. The potential to do aircraft maintenance more efficiently, faster and cheaper thanks to 3D printing of tooling is great.
Alejandro van Meer will give a lecture at AM for Production, 2nd of October about how KLM Engineering & Maintenance uses 3D printing in the maintenance business. More information about the Mikrocentrum congres and expo can be found here.
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