Scope: Developing standardizable quality assurance concepts for additive manufacturing in aviation

SONRISA is submitted as a joint project led by Liebherr-Aerospace Lindenberg GmbH. Funded by the Federal Republic of Germany as part of the LuFoVII-1 call. Funding code: 20X2401C.

Project partners: Bundesanstalt für Materialforschung und -prüfung (Federal Institute for Materials Research and Testing), Boeing Deutschland GmbH, Materialise GmbH, MTU Aero Engines AG.

Associated partner: Carl Zeiss Industrielle Messtechnik GmbH.

The SONRISA joint project will develop digitized, standardizable quality assurance concepts for 3D printing weight-optimized aviation components. Together, the consortium aims to ensure the stability and repeatability of laser powder bed fusion (PBF-LB/M) through in-situ and ex-situ process monitoring and statistical process control, accelerating the approval process as a result.

A robust data infrastructure, advanced analysis methods, and optimized testing concepts will help reduce costs, time, and energy consumption, support international standardization efforts (EASA, FAA), and contribute to sustainability in aviation.?

Scope of the sub-project
As a leading global provider of 3D printing software and services, Materialise's role in the project is to develop a digital concept for the quality assessment of metallic PBF-LB/M components. The fusion and analysis of process and test data (e.g., temperature, image, and CT data) will enable automated, data-based acceptance decisions.

Additionally, we are developing virtual feasibility testing workflows for 3D printing that can make a significant impact during the CAD design phase. We expect this to bring technological and sustainable improvements, strengthen Materialise's methodological basis in quality assurance, and expand the software portfolio for aviation and other certification markets.?

"This project is all about generating trust. We have the chance to play a significant role in shaping how additive manufacturing is seen and adopted in aviation. To prove to the industry that this technology delivers the parts they need, at the quality and price point they demand," says CTO Bart Van der Schueren.

"As the first choice in additive manufacturing for aerospace, Materialise has driven this movement for many years; now, we're excited to see how this project helps the aerospace industry pursue a more sustainable, cost-effective future."