Hexagon and Nikon SLM Solutions print Fuel Air Separator that could reduce Airbus A330 CO2 emissions
The companies achieved a 75% weight reduction on the component that could reduce the lifetime carbon dioxide emissions of an Airbus A330 by 264 tons
Industrial technology giant Hexagon and metal AM specialist Nikon SLM Solutions have used advanced metal AM software and hardware to redesign an Airbus aircraft fuel system component, drastically reducing its weight and creating a pathway to a reduction in carbon dioxide emissions.
The part in question, a Fuel Air Separator, feeds the Airbus A330’s Auxiliary Power Unit (APU). The large and complex component removes air from the APU fuel feed system, allowing it to power aircraft systems when the main engines are off. At present, the part is fabricated from more than 30 individual components that require manual welding and assembly—a process that is both slow and labor-intensive.
Because of these challenges, Airbus Operations and Nikon SLM Solutions initiated a research case study to optimize the production and performance of the air separator by printing it on a Nikon SLM NXG XII 600 system. (In June of this year, Nikon SLM began producing the giant metal AM system in the United States.)
The combination of Hexagon’s software and Nikon SLM’s additive manufacturing hardware enabled the production of the simplified and optimized AM A330 Fuel Air Separator prototype.Â
Key results of the re-design included:
- 75% weight reduction from 35kg to less than 8.8kg
- 30+ individual components consolidated to just one
- 68-hour printing time
- Predicted reduction of lifetime carbon dioxide emissions of an Airbus 330 aircraft by 264 tons
Using simulation-driven design software and other tools
Hexagon’s Design for Additive Manufacturing (DfAM) workflow was key to maximizing the potential of the NXG XII 600, with three Hexagon tools in particular used during the process.Â
Hexagon MSC Apex Generative Design software was used to consolidate over 30 individual components into a single lightweight part that met structural and performance standards; Simufact simulation tools were used to optimize the printing process and predict part deformation; and AMSTUDIO build preparation software was deployed to generate optimal print data and fully exploit the NXG XII 600 for maximum accuracy.
About a year ago, Hexagon introduced its HxGN Additive Manufacturing Suite, comprising the previously mentioned AMSTUDIO and Simufact along with its DESIGNER and ESPRIT EDGE solutions. The end-to-end package aims to deliver “scalability, reliability, and repeatability” to AM users.
Hexagon, Nikon SLM Solutions, and Airbus Operations believe the fuel air separator research project demonstrates the power of combining AM with simulation-driven design. While no concrete plan is in place to use the re-designed part on commercial aircraft, the group says Airbus is “well-positioned to expand these technologies in future aircraft designs.”
