MATERIALS, PROCESSES & FINISHES
pressure to maintain its new shape. The economics and precision of this manufacturing approach is highly valued in industries such as aerospace, defence and even in automotive for creating lightweight, intricate components that are structurally robust, reducing material waste and assembly requirements.” SDE’s new hybrid technique is
estimated to shorten the forming cycle time by over 50% and cut the manufacturing cost by as much as 25% when compared with traditional superplastic forming processes. In terms of applications, the manufacturing method is capable of streamlining the production of a wide range of critical aerospace parts. “SPF is an ideal manufacturing
method for aerospace components, especially suited to create intricate, lightweight parts that off er enhanced structural integrity and performance,” Gill says. “Typical applications include fuselage panels, which benefi t from seamless, aerodynamic surfaces; wing components like skins and fl aps that require precise, lightweight shapes for eff icient fl ight; and engine components such as fan blades and inlet cones, made from heat-resistant alloys. SPF is also used for creating robust door frames, internal structures like bulkheads and brackets, and even seat frames, all of which contribute to
The SPF process is capable of producing highly complex aerospace components
reducing overall aircraft weight while maintaining strength and durability.” According to Gill, the method
streamlines production by integrating multiple features into single components, signifi cantly reducing assembly requirements and material waste.
SIZE MATTERS While SDE’s hybrid SPF technique promises many benefi ts in terms of shortened forming times and
The hybrid SPF process is being developed as part of the NATEP project
reduced material waste, like any manufacturing technique it is not without its limitations. “SPF does has size limitations on the
parts it can produce, primarily dictated by the capabilities of the equipment used and the physical properties of the materials,” Gill explains. “The limitations are in common with other material processes where the size of the furnace is a critical factor. Also, the larger the parent sheets then the
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