The Aerospace industry has been at the forefront of adapting Metal Additive Manufacturing (AM) and some of the most evolved applications of metal AM can be found in the aerospace sector. Leading OEMs, tier 1 suppliers, and key ecosystem players are in the phase of developing mature capabilities in metal AM. Typical value contribution from Metal Additive Manufacturing comes in the form of weight reduction, reduction in sub-assembled parts by creating monolithic designs, ability to realize complex designs and drastic reduction in lead-time to realize components.
Typical applications involve a range of components such as compressor stators, combustion chambers, impellers, turbine blades, nozzle guide vanes, diffusers, volute casings, elements of anti-icing systems, and light structural components (including brackets). Many of these applications in different engine platforms are actually proven out to be flightworthy.

From brackets to compressor stator rings, across a range of metal alloys, Wipro 3D has developed and delivered flightworthy applications of metal AM that have met stringent prove out customer requirements. Design for AM or additive engineering as we call it, requires a good understanding of the application, relevant metallurgy, and expert-level control on Additive Manufacturing technology. Wipro delivers a complete solution, from topology optimization and additive reengineering right through to prove out of customer’s components.

Wipro 3D has reimagined and delivered components for a leading Aerospace OEM that have reduced the customer’s “design to realize” lifecycles by as much as half or more. While the AM industry continues to work towards 'mainstreaming' the technology, Wipro 3D has developed the capability to understand target, prove out requirements and deliver solutions to our clients using our own practices in Addictive Engineering, metallurgical handling of builds, coordinated post processing, and a prove-out ecosystem that leverages in-house and partner facilities. Apart from Ti6Al4V, Inconel 625 and 718, Wipro 3D offers the ability to adapt new alloys, based on customer applications and business case. Based on our first-hand research, we have developed a robust domain understanding in aerospace. Our technology advisors come with unparalleled expertise and this helps us deliver right solutions to our customers.

Wipro is deeply engaged in the aerospace sector and in addition to our AM Business, we operate state-of-the-art facilities certified by global players such as Messier Bugatti Dowty, UTAS, and Liebherr for manufacturing, assembling, and testing of aerospace actuators and precision machined components, based on a technology transfer agreement with CESA, Spain.

Aerospace case studies

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