- The future of aerospace propulsion needs to be designed more sustainable - it is our challenge to move towards zero emissions and carbon neutrality
- The increasing demand for CO2 reduction created a subsequent demand for eco-efficiency and alternative powertrain concepts
- New materials and production technologies: Potential for new aerodynamic designs and reduced fuel consumptions
Setting new trends for the aerospace industry with large additive solutions like turbine rear vanes
We help you to move your application to additive manufacturing
The additive manufacturing process maximizes the design flexibility and allows the integration of additional functions - at no additional costs for extra geometry changes as no prior models or tools are needed. Geometries are no longer limited to the possibilities of traditional technologies.
In addition, with printing space as big as 500 x 500 x 500 mm, we offer serial production of large additive manufactured components with extremely complex shapes integrating more details and functions.
With printing space of 500x500x500mm, large dimensions are possible.
Additive manufacturing with GF
We help you to travel more efficient and clean
- We support you with long-standing experience from decades!
‒ From the very first design concept to serial production
‒ With complex geometries
‒ Different sizes of up to 500 x 500 x 500 mm
‒ NADCAP quality levels
- With lightweighting through additive manufacturing as well as our highly-stressable precision casting solutions, we are a reliable partner in the development of new engines.
Our offer
Our expert teams and certified manufacturing environment are ready to realize your 3D-printing challenge.
In the following, we describe our key features and technologies behind optimized aerospace solutions like the 3D-printed GF turbine rear vane.
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In-house development and validation expertise
Characterization of material properties
Support and consulting in the product development process
Additive Manufacturing oriented and compliant designs
Integration of additional functions and neighbour parts
Topology optimization and FEM simulation
Static and dynamic validation of components also under thermal boundary conditions
Leakage testing
Metallurgical analysis of components
High design freedom
- High focus on the part functionality
- Extreme shapes
- Topological optimization and possibility to integrate lattice structure: Reducing weight and material
- Maximal design freedom thanks to additive manufacturing
- Benefits:
‒ Cost reduction as mating surfaces no longer need to be machined to tight tolerances
‒ Reduced lead time compared to functional surface creation via casting
‒ Cost-neutral feature
‒ Possibility to create closed cavities without the need of molding or post-processing
High functional integration
- Integrating six single parts into one design
- Reduction of weldingto attach double-walled heat shiels for joint/assembly activities and process steps e.g. tooling or machining processes
- Increased overall reliability due to single-piece production
- Recuded leakage risk at the interface between different parts
Higher level of performance
- Increased air flow through the cylinders’ combustion chamber augments the engine power output
- Reduced weight of the usually heavy doubled walls while achieving the thermal insulation required for optimal performance thanks to an air gap which is not feasible with traditional casting methods
- Increased flexibility because of short production lead time
- Cost advantage: not only within the geometry and performance of the application but cost savings through the reduction of process steps such as machining
Material properties
Density: almost no inner porosities (in AM evenly >99.5)
Depending on material and scope, AM can avoid HIP-treatment (cost intensive process step)
Microstructure is finer than cast ones: the tensile strength of AM material is higher
High repeatability in Additive Manufacturing
Value add in additive manufacturing
Find the right technology for your project
Additive manufacturing or precision casting?
The choice for the perfect technology depends on the specific project requirements and needs. GF brings long-standing experience with similar component families from the casting process which is now built upon when offering additive solutions: of course at the same high quality level.
Our post processing capabilities
- Vacuum & cryogenic heat treatment
- NDT inspection
(including analog & digital RX, FPI, 3D measurement, CMM, bluelight scanner measurements system, and electronic gauges) - Welding
- Airflow test
- Installation for chemical etching
- Surface superfinishing processes
- Finishing and polishing (more than 50 years of experience)
- HIP**
- Computer tomography**
- Machining for semi-finished and finished components**
** not in-house
