When air flow is key to the function of a part, these days, additive manufacturing is never far from the manufacturer's thoughts.
It may only take a single compromise or a single additional step in the workflow for a manufacturer to consider their options.
And so was the case when a prominent aerospace OEM specialising in light aircraft assessed the existing manufacturing approach of a helicopter intake duct. The part was performant, and the workflow was fairly standard. But if there was an opportunity for an alternative process to optimise the process and bring about cost and performance benefits, the manufacturer wanted to explore it.
The part's function
The combustion chamber engines that are typically deployed in helicopters rely on an oxidiser to enable fuel combustion. By directing external air towards the engine, intake ducts, therefore, serve an important function in the performance, efficiency and safety of flight operations.
