Laser DED additive manufacturing: Spar frame (aerospace)

Structural components in TA6V have particularly long lead times when produced by forging, often exceeding 18 months. The aim is to secure the supply chain by producing large blanks (> 1 m) while guaranteeing mechanical properties compatible with aerospace requirements.

IREPA LASER manufactures blanks using powder-fed laser DED, sized for subsequent machining. The approach is supplemented by numerical simulation to anticipate distortion and adapt the process strategy to large dimensions

Manufacturing large parts requires precise control of distortion as well as control of machining allowances and material quality to secure machining operations. The developments carried out also ensure mechanical properties that meet tensile and fatigue requirements.

The solution reduces lead times from over 18 months to less than 3 months. The blanks produced are fully ready for machining, with validated mechanical performance (tensile, fatigue) compliant with specifications.