Hexagon’s Manufacturing Intelligence division and Nikon SLM have collaborated to redesign a large fabricated aircraft fuel system component using design freedom of additive manufacturing. Using Hexagon’s simulation-led Design for Additive Manufacturing (DfAM) toolchain and Nikon SLM’s advanced multi-laser metal additive manufacturing technology achieved significant lightweighting, part consolidation and precise geometric tolerances.
Airbus Operations used the technology from its partners to redesign a Fuel Air Separator – a component that feeds the Airbus A330’s Auxiliary Power Unit (APU). The combination of Hexagon’s software and Nikon SLM’s additive manufacturing technology has enabled the production of the simplified, more efficient AM A330 Fuel Air Separator prototype. This re-design achieved a 75% weight reduction from 35kg to less than 8.8kg, setting a new precedent for use of additive manufacturing and simulation-driven design in the aerospace industry.
The fuel air separator is a large, complex component that removes air from the APU fuel feed system, ensuring the APU can power essential aircraft systems when the main engines are off. The conventional part is fabricated from more than 30 individual components that require manual welding and assembly. This process is labour-intensive, which results in long lead times, and limits the potential for design improvements.
Airbus Operations and Nikon SLM initiated the research case study to optimise the production and performance of the air separator, creating an innovative process that used Nikon SLM's latest NXG XII 600 system – a large-format, multi-laser 3D printer – to simplify manufacturing, reduce lead times and streamline installation.
Simulation-driven redesign unlocks design freedom
The team called upon Hexagon to redesign the part using a Design for Additive Manufacturing (DfAM) workflow to maximise the potential of the advanced 3D printing system. Using Hexagon’s MSC Apex Generative Design software, they consolidated over 30 individual components into a single lightweight part that met all necessary structural and performance standards. Hexagon’s Simufact simulation tools were then used to optimise the printing process and predict part deformation, ensuring that precise geometric tolerances were maintained. Global tolerances were controlled to +/- 5 mm, with critical functional surfaces refined to +/- 0.5 mm to ensure seamless compatibility with the aircraft’s fuel system.
Simulation-driven design allowed for part optimisation while adhering to the stringent aerospace regulatory requirements. The additive manufacturing technology employed significantly reduced lead time by combining multiple manual processes and reducing production time. The large part was produced in just 68 hours, using optimised print data from Hexagon’s AMSTUDIO build preparation software to fully utilise the NXG XII 600 powder bed fusion printer and maintain precise geometric accuracy.
Advanced manufacturing drives sustainability innovation
The reduced part weight, decreased manufacturing lead time and enhanced efficiency gained through the manufacturing process contribute to lower fuel consumption.
The collaboration between these industry leaders has simplified production, enhanced performance, and set new benchmarks for efficiency. This project demonstrates the power of combining additive manufacturing with simulation-driven design, and Airbus is well-positioned to expand these technologies in future aircraft designs.
