Liebherr-Aerospace advances additive manufacturing for Airbus A350

Liebherr-Aerospace has taken a significant step forward in the additive manufacturing of complex parts for aerospace applications. The first-tier supplier has successfully integrated a 3-D printed flex shaft into the Airbus A350 high-lift system. This unit has been approved by both Airbus and the European Union Aviation Safety Agency (EASA) for serial production.

Liebherr-Aerospace continues to advance its expertise in 3-D printing. The company has recently celebrated a new milestone: the successful production of a flex shaft, a highly complex component made from titanium powder using additive layer manufacturing (ALM). Both Airbus and EASA have approved this flex shaft for series production.

The innovative design options provided by ALM allowed Liebherr to replace an assembly of seven conventionally manufactured parts with a single 3-D printed component. This reduction in parts improves reliability and significantly reduces weight. Compared to previously developed and manufactured 3-D printed parts, the flex shaft represents a new level of complexity, marking a significant step towards applications in highly integrated systems.

The flex shaft is part of the Airbus A350 high lift system, where it will be integrated into the active differential gearbox of the flap system. It transmits the rotary movement to a position sensor, compensating for angle and axis misalignment between the gearbox and the sensor.

Liebherr-Aerospace already boasts an impressive range of products manufactured using ALM. In early 2019, for instance, Liebherr-Aerospace began serial production of 3-D printed parts with the introduction of a printed proximity sensor bracket for the A350 nose landing gear. This bracket was the first-ever Airbus system part qualified for titanium additive layer manufacturing.