High Pressure
Compressor Stator
The Stator converts kinetic energy into static pressure
CATEGORY
Aerospace
MATERIAL
Ti6Al4V
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 T Manufacturing comes in 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.
About the Project
AM Competencies Used
Additive Design & Engineering
Due to it’s large size, the Stator was creatively sectioned into different zones to achieve the desired geometry, dimensions and functionality.
Post Processing
A series of well-planned post processing activities were coordinated and executed to achieve the Stator’s desired features critical to performance i.e. pe particularly surface finish and weight.
AM Value Addition
Design Freedom
Time-to-realize
The complete design to realize lifecycle for the Combustion Chamber was done in less than 5 months, a drastic time compression compared to the traditional 14 months.
Other Case Studies
Antenna Integrated Helix Feed
Additive Manufacturing is reaching outer space. With increased effectiveness and maturity of space programs all over the world, leaders in the space community, are innovating, developing and iterating on multiple frontiers that lead to faster and cheaper deployment of payloads . The Wipro 3D has re-engineered, developed, and proved out flight-ready components in short “re-design to realize” lifecycles to meet such requirements.
Private space enterprises, state-run-space organizations, and other members of the space industrial ecosystems are replacing existing and conventional geometries, with designs using the freedom of design that Additive Manufacturing brings, leading to significant impact on performance. Components such as antennae, wave guides, brackets, thrusters, main oxidizer valves, combustion chamber liners, and propellant injectors, are either in the prototyping stage or are actually flying.
Oil Intake Manifold
In the highly competitive auto industry, speed to market, high strength to weight ratios, fuel efficiency are some of the few goals that constantly drive engineers and designers. New high-strength steels, along with composites and adhesives, are helping to reduce weight and increase strength in modern vehicles. Additive Manufacturing using metal alloys, has found interesting applications in tooling, jigs and fixtures, and design prototypes allowing companies to iterate rapidly and validate designs of components and subsystems. While metal Additive Manufacturing of co components at the production scale of automotive may be challenging, there are certainly emerging applications in the low volume, higher end of the industry including Formula 1 and military vehicles.
Additive Manufacturing allows optimizing the maximum strength with minimum weight and material (Topology Optimization) owing to the potential to handle complex geometries. "Monolithizing" sub-components or child parts into a monolith assembly reduces production time, improves functional performance. Typical applications of Metal AM in Automotive are weight optimized manifolds, turbine housings that form part of the current turbo powertrain ERS systems, water-wheel pumps , aluminum axle pivots. A leading name in industry has developed rocker arms and camshaft bearing caps using Metal Additive Manufacturing for its next generation truck engines.
Closed Impeller
Additive Manufacturing is reaching outer space. With increased effectiveness and maturity of space programs all over the world, leaders in the space community, are innovating, developing and iterating on multiple frontiers that lead to faster and cheaper deployment of payloads . The Wipro 3D has re-engineered, developed, and proved out flight-ready components in short “re-design to realize” lifecycles to meet such requirements.
Private space enterprises, state-run-space organizations, and other members of the space industrial ecosystems are replacing existing and conventional geometries, with designs using the freedom of design that Additive Manufacturing brings, leading to significant impact on performance. Components such as antennae, wave guides, brackets, thrusters, main oxidizer valves, combustion br chamber liners, and propellant injectors, are either in the prototyping stage or are actually flying.
North West Feed Cluster 2x2
Additive Manufacturing is reaching outer space. Where every gram counts, in an environment with extreme cyclic temperature variations and harsh forces during the launch, the functional life of components is a critical part of design considerations. Wipro 3D has re-engineered, developed, and proved out flight-ready components in short “re-design to realize” lifecycles.
Private space enterprises, state-run-space organizations, and other members of the space industrial ecosystems are replacing existing and conventional geometries, with designs using the freedom of design that Additive Manufacturing brings, leading to significant impact on performance. Components such as antennae, wave guides, brackets, thrusters, main oxidizer valves, combustion br chamber liners, and propellant injectors, are either in the prototyping stage or are actually flying.