ACI Jet is implementing additive manufacturing capabilities within the maintenance arm of its business. Additive manufacturing, or 3D printing, allows parts and components to be produced through the addition of raw materials from a CAD rendering instead of by way of subtracting material. A hybrid material called Acrylonitrile Butadiene Styrene is used in accordance with FAR Part 25.853 for aircraft components as it contains 10 percent flame-retardant additives.
“As 3D printing has found its place in product development and mass production, its benefits to the maintenance and repair functions of private aviation have only recently started to take shape. The savings are twofold: time and money,” said Brian Ford, avionics supervisor at ACI Jet.
Like other components designed based upon engineering drawings, 3D-printed parts are also subject to a quality control process. “To have the capability to fabricate parts in accordance with engineering drawings in-house, and for duplication as needed, is fantastic. The actual fabrication process is automated while other work is being performed,” said Ford. “We can also run prototypes for modifications and repairs on site, and for a fraction of the cost that comes with legacy fabrication methods.”
The company uses a LulzBot Mini 2 to complete the additive manufacturing process. ACI Jet has manufactured iPod charging mounts for cabin management systems in Bombardier Globals and Challengers. Additionally, the company has created molds for carbon-fiber outlet escutcheons for Challenger 604s along with other tooling applications.
“We’re always seeking to expand our capabilities, to get more done in-house to minimize downtime for our clients,” said Dave Jensen, ACI Jet’s vice president of aircraft maintenance. “Additive manufacturing was a great fit because we have the right minds, the right energy within our team, to think outside the box, in order to find solutions that save our clients time and money. It’s a perfect fit and something that will definitely be the standard in maintenance hangars going forward.”
