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teaming provides a value-based offering that is rooted in the core competencies they each do well, RUAG with engineer- ing and topology optimization and Morf3D with system-wide program management and parts production RUAG has outstanding technological capabilities on the


ground, in the air and in space. Today, about 8000 committed and skilled staff at the production locations in Switzerland, Germany, Sweden, France, Austria, Hungary, Australia and the US are driving forward the technologies of tomorrow. RUAG is comprised of fi ve business divisions focused on


Aerostructures, Aviation, Defense, Ammotec and Space. Specifi cally, RUAG Space is Europe’s largest independent supplier of space products to the industry. For institutional and commercial customers RUAG Space offers a broad product portfolio, which is structured into the following prod- uct areas: • Launcher Structures & Separation Systems


• Satellite Structures, Mechanisms and Mechanical Equip- ment • Digital Electronics for Satellites and Launchers • Satellite Communication Equipment • Satellite Instruments


Unleashing the Full Potential of Additive Engineering Leveraging a strong history of engineering success, RUAG Space, led by General Manager of Structures, Franck Mouri- aux and Director of RUAG Space USA, Albert Lepore, Jr., set their sights on becoming a leader in designing for additive manufacturing. RUAG has invested in developing capabilities that take full advantage of designing for additive manufactur- ing and have developed world-class processes that provide the essential data analysis and tools required for many additively designed parts, with particular skills developed in topology optimization.


These tools and frameworks are fundamental for under- standing the shift that needs to occur to design for additive, understand the processes required to validate a part, and ac- tually design and produce parts with a fully optimized design. RUAG has a staff of mechanical engineers, designers, ma- terial and process engineers, and PA engineers, specializing in the design, analysis, manufacturing and testing of light- weight structures for space and nonspace applications. Their expertise in the optimization of structures will enable custom- ers to fully unleash and exploit AM technology to improve cost and performance. Through the collaborative efforts of RUAG Space and Morf3D, clients are now able to take full advantage of expertise that would normally take years.


Fine-Tuning the Ecosystem


Morf3D has made an initial investment in EOS systems for metal manufacturing. These systems will allow Morf3D and RUAG to offer clients design and build-to-spec services together.


Coauthors RUAG Space USA Director, Technologies and Programs Al Lepore (left) and Morf3D Chief Engagement Offi cer Ivan Madera with a 3D-printed satellite component.


Using a process for imagining—called “Envision. Evolve.


Emerge.”—clients are fi rst led through analysis and creative exploration processes to establish a strategy for additive manufacturing, and then carry it through to implementation and production of parts. The resulting analysis yields multiple scenarios for developing a new additive manufacturing and supply-chain business case. This is particularly important as companies accelerate the exploration of determining how and where and at what level to invest in additive manufacturing capabilities. From incremental steps to rapid deployments, collectively Morf3D and RUAG are able to provide clients with quantita- tive data and jointly develop the most value-added scenarios which become the basis for investment. Clients are offered the guidance needed to determine candidate part selection, which programs to invest, or which product families offer the biggest benefi t by a total redesign.


Morf3D and RUAG plan to demonstrate how this is just the beginning of building ecosystems that will drive the growth of the additive industry. Allowing each contributor to focus on what they do best, and come together to create a total capability greater than the sum of each individual part—just like nature’s ecosystems are a collection of many different capabilities.


85 — Aerospace & Defense Manufacturing 2015


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