Stratasys Aircraft Interiors Certification Solution
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SOLUTION GUIDE Certified Additive Manufacturing for Aircraft Interiors THE CERTIFICATION CHALLENGE Additive manufacturing (AM) processes and materials pose real benefits for the aerospace industry through manufacturing, performance and supply chain improvements. However, certification of AM aircraft parts is currently a challenging, if not ambiguous endeavor for aerospace companies. The primary reason is the lack of an established certification roadmap and qualified materials. Companies may be experienced with AM but aren’t aware of the critical aspects of this technology as it relates to aircraft certification. The result is a lack of specific guidelines and specifications needed to satisfy the certification communities. Then there are those familiar with the certification process but still see it through a traditional manufacturing lens, and lack the experience needed to translate the critical elements to the AM world. Also lacking is a database of AM material properties that engineers can use to design and develop aircraft parts using the AM process. The absence of material property data means aircraft companies are left to develop this information on their own, a process that can be extremely expensive and time consuming. Consequently, companies that assume this challenge and develop their own data typically view it as proprietary information, which isn’t shared with the broader aerospace community. This creates an environment where all industry participants are forced to create their own data and processes, resulting in variability and a lack of material and process standards. THE SOLUTION In response to this challenge, Stratasys worked together with the aerospace and certification communities to foster a collective understanding of what’s needed to create a certification path for additively manufactured parts supported by all parties. To that end, Stratasys developed the Aircraft Interior Certification Solution (AICS). It includes a a specially configured Fortus 900mc™ Production System to ensure consistent, reliable build results, and a design allowables dataset for FDM® ULTEM™ 9085 resin material. This product gives aerospace companies the material, process and standards needed to develop AM parts for aircraft installation. The design allowables, developed using the NCAMP (National Center for Advanced Materials Performance) process with FAA oversight, will reside in the public domain, accessible to any aerospace company. Stratasys provides the certified ULTEM 9085 resin material, the production system configuration and the support necessary to qualify any Fortus 900mc to perform equivalency to the original dataset.

CERTIFIED ADDITIVE MANUFACTURING FOR AIRCRAFT INTERIORS WHAT’S INCLUDED The AICS product consists of the following components: • Material and process specifications • Certified ULTEM 9085 resin material • Aircraft Interiors Configuration Fortus 900mc (or upgrade) • B-Basis design allowables dataset • Process guidance on system qualification for equivalency tests Material and Process Specifications The Material Specification governs the production of raw ULTEM 9085 resin and its conversion to filament. It focuses on the critical characteristics of upstream raw stock to ensure a high-quality...

CERTIFIED ADDITIVE MANUFACTURING FOR AIRCRAFT INTERIORS The information contained in these documents form a complete chain of traceability from the raw ULTEM 9085 resin pellets to the manufactured FDM filament spool. Examples of Certificates of Analysis and Conformance Aircraft Interiors Configuration Fortus 900mc Another foundational element of the AICS product is the Aircraft Interiors Configuration Fortus 900mc. This specially configured configuration is needed to produce consistent, reliable build results with certified ULTEM 9085 resin. It is available as a newly purchased production...

CERTIFIED ADDITIVE MANUFACTURING FOR AIRCRAFT INTERIORS The following material properties are tested for each of three lots of material: Flammability Drip Time Flammability Extinguishing Time Flammability Burn Length Heat Release Peak Specific Gravity Flexural Strength and Modulus Tensile Strength and Modulus In addition to these tests, a subset of coupons from each 3D production system and each lot is tested to determine the following properties: ASTM D3171-11/or applicable mechanical test method. Glass Transition Temperature, Tg by DMA flexural loading * Where the applicable standard...

CERTIFIED ADDITIVE MANUFACTURING FOR AIRCRAFT INTERIORS Another subset of coupons from each system and test lot is tested to determine the following material properties: Number of Lots x Number of Machines x Number of Coupons Test Type ASTM D5766 Open Hole Tension (1) X ASTM D5766 Open Hole Tension (1) Y ASTM D5766 Open Hole Tension (1) Z ASTM D5766 Open Hole Tension (1) Z (45) ASTM D6742 Filled Hole Tension (2) X ASTM D6742 Filled Hole Tension (2) Y ASTM D6742 Filled Hole Tension (2) Z ASTM D6742 Filled Hole Tension (2) Z (45) ASTM D6484 Open Hole Compression (1) X ASTM D6484 Open Hole...

CERTIFIED ADDITIVE MANUFACTURING FOR AIRCRAFT INTERIORS Finally, a set of test coupons is tested for fluid sensitivity. Extended Contact 100 Low Lead Aviation Fuel (ASTM D910) ASTM D1655 Jet A Fuel (other jet fuel may be used but its type must be reported) MIL-PRF-5606 Hydraulic Oil MIL-PRF-83282 Hydraulic Oil Test Condition 50% Water with 50% Skydrol LD-4 (SAE AS1241, Type IV, Class 1) Short Duration Contact Test Condition MIL-PRF-7808 Engine Oil MIL-PRF-23699, Class STD Engine Oil Sea Water (ASTM D1141 or equiv.) Skydrol LD-4 (SAE AS1241, Type IV, Class 1) MEK washing fluid. ASTM D740...

CERTIFIED ADDITIVE MANUFACTURING FOR AIRCRAFT INTERIORS HOW IT HELPS The Aircraft Interior Certification Solution gives aerospace companies the tools and process for achieving certification of additively manufactured parts for aircraft installation using NCAMP-qualified ULTEM 9085 resin material. The product creates a clear process path for part certification and avoids the need for companies to create their own set of design allowables. Instead, they simply need to show equivalency to a much smaller test lot using the Aircraft Interiors Configuration Fortus 900mc. The combination of the...