Etihad Engineering, EOS and Baltic3D to serially manufacture AM parts for aviation

Etihad Engineering, the largest commercial aircraft maintenance, repair and overhaul (MRO) services provider in the Middle East, EOS, the leading supplier of manufacturing solutions based on industrial 3D printing technology, and Baltic3D.eu, one of the largest industrial 3D printing centers in Northern Europe, have agreed to collaborate on a  Research and Development project “FDM and SLS industrial 3D printing technology applicability in serial manufacturing of aircraft interior parts”.

Baltic3D has selected laser sintering (SLS) technology from EOS, among other powder bed solutions, as a key competence partner, considering EOS’s achievements in terms of their technology and materials qualification for aerospace applications. Meanwhile, Etihad Engineering, as an industry leader implementing additive manufacturing (AM) technologies in aerospace applications, will be supporting the joint R&D efforts by conducting flammability testing at its onsite Flammability Laboratory, and providing its engineering analysis and reports, as feedback on the designs and prototypes produced within the project.

Within the R&D project, Baltic3D will print over 2,000 material coupons using the EOS P 396 machine using SLS technology. These material samples will be tested at the Etihad Engineering Flammability Laboratory in Abu Dhabi by aviation standards, including FST and heat release tests. Then, several prototypes for aircraft interior part designs will be created using LS technology.

Janis Jātnieks, co-founder and Board member of Baltic3D, said, “From part design to the end part manufacturing and certification, the aviation supply chain is heavily hit by COVID-19. With this R&D project, we aim to significantly reduce time and money for design organizations and OEMs, as they have to invest in additive manufacturing as an additional manufacturing route to existing production or even completely switch to complex parts production using AM. We plan to establish a comprehensive test and manufacturing data set that would help aerospace engineers develop part designs for AM with high confidence.”

Markus Glasser, Senior Vice President EMEA at EOS, added: “EOS constantly strives to be the most trusted partner with proven and reliable technology, continuously complying with the aerospace industry’s requirements. Over the last few years, we have fully qualified our technology, meaning qualified materials, processes and systems for the aerospace world. Aerospace demands reliable data, which is the primary aim of this project, and thereby, we firmly believe that this project will substantially accelerate the adoption of AM in aerospace.

He continues: “Baltic3D intends to increase access to 3D printing know-how and test results to make the adoption of industrial 3D printing faster and easier for any aviation company. We share the same mindset, as both companies are committed to the highest quality solutions for our customers and constant technology innovation and cost reduction for complex parts. We look forward to supporting Baltic3D and Etihad on this innovation journey, bringing the production of aircraft interior parts closer to true serial additive manufacturing.

Ahmad Rajei, Acting Vice President Design, Engineering and Innovation, Etihad Engineering, said: “As the first MRO airline in the Middle East to receive EASA approval to design, produce and certify 3D printed cabin parts, we are delighted to support Baltic3D and EOS. The launch of this R&D initiative aligns with Etihad Engineering’s position as a leading global player in aircraft engineering and a pioneer in innovation and technology.”