The Challenge
Our current manufacturing route for large titanium structures requires large forgings, which come with multi-year lead times that can be subject to design freezes. We rely on what is known as subtractive manufacturing – starting out with a large amount of titanium and cutting and shaping it until you have the component you need. This come with large amounts of wastage and because designs are frozen early on, optimisations may not be fully realised, meaning there’s a huge amount of scope for leaner manufacturing processes through research and development.
The solution
Titanium wire and other material feedstock are already available commercially, as well as having a strong, existing supply chain behind them. We collaborated with Cranfield University to apply an additive manufacturing process that they were developing and using with focus on aerospace manufacturing. This involved collaborating in a development programme that helped to produce Wire Arc Additive Manufacturing methods for different use cases – culminating in a Typhoon Rear Frame that’s now on display in Samlesbury. Working with academics at Cranfield University, we helped to provide the university with an application focus for aerospace manufacturing by providing funding for projects and PhDs since 2005.