This project demonstrated the potential of replacing conventional manufacturing techniques with Wire and Arc Additive Manufacturing (WAAM) to produce large aluminium components for the space sector.

Key Facts

    • Date range: 2021 to 2023
    • The largest and most complex aluminium demonstrator ever 3D printed within our Welding and Additive Manufacturing Centre at 扣扣传媒 was produced.
    • The component was a 50% scaled aluminium bulkhead, currently manufactured via forging and machining. The 1.2 by 1.2 by 0.8 meter and 450 kg WAAM part is near-net-shape and requires a final machining step by Thales Alenia Space to produce the final component.
    • Building sequence design, tooling development, numerical simulation, in-situ machining, and stress-release heat treatment were successfully implemented to build a demonstrator with minimum distortions.
    • Our life cycle assessment shows that if WAAM were used to produce a full-size aluminium bulkhead, CO2 emissions could be reduced by 90% compared to conventional manufacturing processes. Moreover, lead time and costs could be consistently reduced.

Impact of our research

Our research demonstrates the potential of metal 3D printing to manufacture real parts, which is critical to building confidence and enabling the technology to be adopted in the industry. At Cranfield, part building is essential to understand the challenges faced while manufacturing parts, which fundamentally differ from those encountered while manufacturing test pieces. This project demonstrated the possibility of building complex parts with minimum distortions using numerical models to design the deposition sequence. Dr Filomeno Martina, CEO and co-founder of WAAM3D, stated: 鈥淪pace is an industry with a huge amount of potential for our WAAM process. However, to seriously deploy such technology, we must validate the capability to produce structures of relevant size and complexity with the right mechanical properties. This project has taken a fundamental step that brings us closer to this vision, and we are very grateful to Thales Alenia Space for funding this work and 扣扣传媒 for being such a formidable ally.鈥�

The successful implementation of the WAAM and machining combination also led to more joint industry projects, as the three partners are now exploring this method to repair aluminium components.

Why the research was commissioned

New designs and modifications of low-volume, complex components occur regularly within the space sector. Conventional processes, such as forging and subtractive manufacturing, are often expensive, have extended lead times of 12-18 months, and lack flexibility when implementing design modifications. Alternatively, WAAM offers flexibility for design and manufacture and can reduce lead times from months to weeks, increasing resilience. Sustainability is now a critical factor, and machining large quantities of material to be recycled is no longer acceptable. WAAM drastically reduces raw material consumption: for a full-size bulkhead, WAAM is expected to reduce the raw material need by 90%, from more than 5 tons to 500kg.

Thales Alenia Space funded this project within the frame of its initiatives related to Additive Manufacturing. WAAM has been shown to be a promising technology for several Thales Alenia Space products, particularly for large, complex infrastructures.

Why Cranfield?

The Welding and Additive Manufacturing Centre (WAMC) at 扣扣传媒 produce a wide range of demonstrator parts for its industry partners, including a rear frame for a Eurofighter Typhoon for BAE System. The WAMC is internationally recognised as a centre of excellence for WAAM, as shown by its integration into Avio Aero鈥檚 European Technology Development Clusters. In 2018, WAAM3D Ltd was formed as a spin-out of 扣扣传媒 to provide complete technical and turn-key solutions to the industry. Thales Alenia Space recognised the benefit of working with 扣扣传媒 and WAAM3D for the renowned know-how on WAAM, and previous successful experience with the Titanium vessel and for the attention to supporting industrial needs.

About Thales Alenia Space

Drawing on over 40 years of experience and a unique combination of skills, expertise and cultures, Thales Alenia Space delivers cost-effective solutions for telecommunications, navigation, Earth observation, environmental management, exploration, science and orbital infrastructures. Governments and private industry alike count on Thales Alenia Space to design and build satellite-based systems that provide anytime, anywhere connections and positioning, monitor our planet, enhance management of its resources and explore our Solar System and beyond. Thales Alenia Space sees space as a new horizon, helping to build a better, more sustainable life on Earth. A joint venture between Thales (67%) and Leonardo (33%), Thales Alenia Space also teams up with Telespazio to form the parent companies鈥� Space Alliance, which offers a complete range of services.