Additive solutions for aerospace

It is our challenge to design more sustainable propulsion systems for the aerospace industry - additive technologies and their advantages are key to contribute to sustainability.

  • 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
The future of aviation propulsion needs to be designed more sustainable

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. 

GF Casting Solutions aerospace part dimensions With printing space of 500x500x500mm, large dimensions are possible.
Material

Inconel 718

Density

8.2 g/cm³

Weight

7.3 kg

Volume

899.540 cm³

Dimensions

499.7 x 499.7 x 96 mm

Printing time

48 hours

Additive manufacturing with GF

GF Casting Solutions produces components for the aerospace industry.

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
Our central R&D team can set up and optimize your solution - for additive manufacturing as well as for casting processes.

  • 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
Complex and extreme shapes from thick to hollow and thin-walled in one part.
  • 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
With product development and process expertise, we can integrate multiple single parts into one design.
  • 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
Additive manufacturing enables functions such as optimized cooling and can be applied exactly where it is needed.
  • 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
The tensile strength of additive manufacturing material is higher and the microstructure is finer than casting.

  • 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 

Big parts or high quantity

Part size or quantity - We think big! In our 500 x 500 x 500 mm printing space, big and heavy parts are possible as well as small parts in big volumes (part quantity in one print job).

Best choice of technology

Finding the best solution! We make objective & reliable technical decisions regarding manufacturing technology (additive manufacturing vs. casting) and have experience in customer applications, processes and production costs. Both technologies and all post-processing steps happen under one roof.

Fully certified value chain

Quality you can rely on! Our complete additive manufacturing and follow-up processes are certified according to EN 9100 and Nadcap. Our trained and experienced teams take care of handling critical and complex parts requiring the higest standards.

Consulting & development services

We team up with you! We offer full R&D Service, including material, process and design development; and excellent project management. We consult and support during the set-up of specifications.

Cost-efficient all-in-one solution

We offer all post-processes in-house (HT, ST, non-destructive testing) and combine more than 20 years experience in casting parts for rocket propulsion with high-end additive maufacturing technology. Our transparent and reliable services and cost structures allow you to fully focus on the race to space.

We accelerare your time-to-market

Need to speed up your manufacturing processes? Benefit from fast turnaround time and a single point of contact: From the concept to the serial production. Our processes are independent from third parties: All processes from development to finishing take place under one roof.

Value add in precision casting

Wax room

Shell injection

Foundry

Knock-out, cutting, grinding

Finishing & welding

Heat treatment

Fluid penetrant inspection

X-ray

Dimensional control

Value add in additive manufacturing

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Print job preparation

With state-of-the-art tools and proven expertise, our additive manufacturing team takes care of the print job preparation to make sure that the process can run properly. 

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Preparing the printer

We provide the printer with the right powder, clean the optic lenses and take care of the machine calibration.

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Print job

The laser is directly melting the component layer by layer. The remaining powder can be reused after a dedicated sieving process.

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Depowdering (automated)

Once the print job is completed, powder and component are separated automatically and individually. 

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Cutting (Wire EDM)

Wire EDM technology enables to achieve extreme accuracy.

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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.

lupe Concept

To start with a concept, we always take a look at cost efficiency, a component's lifetime, number of parts, geometry and part size.

Casting technology

Depending on your project, precision casting might be the right choice.

Additive manufacturing

Benefit from breathtaking speed and flexibility of the additive manufacturing process. With an expert team and certification, we develop and support your 3D-printing project.

value-bar-icon-gear2 Post-Processes

All of our post-processing capabilities are Nadcap certified, including heat treatment, NDT inspection, welding, or airflow tests.

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

A GF colleague from Novazzano controlling a big machine in post processing.

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