APPLICATIONS In aerospace, critical components must meet exceptional standards of precision, strength, and reliability - characteristics that are equally vital in hydraulic and pneumatic systems. Advanced manufacturing techniques, such as additive manufacturing (AM), are revolutionising precision component production across industries. This case study highlights how Tronosjet Manufacturing achieved FAA certification for a vital aerospace part using AM techniques. While the focus is on an aerospace application, the engineering principles and regulatory challenges described here resonate with the demands faced by fluid power systems in highstakes environments like aviation. Founded in 2001, Tronosjet Manufacturing is a Canadian company specialising in aircraft leasing, major modifications, and maintenance. Historically, the company has managed a fleet of over 60 BAe 146/Avro RJ aircraft, including engines and spare parts. In 2016, Tronosjet expanded its operations by establishing an advanced manufacturing division to produce aerospace components using additive manufacturing. The division offers a complete AM service, including design, printing, heat treatment, post-processing, and metallurgical testing. Its facility is certified as an Aerospace Manufacturing Organisation under Transport Canada 561 and holds AS9100 approval for design and development. Despite AM’s growing adoption, very few components have received FAA approval, which prevents many customers from flying them. To showcase AM’s potential, Tronosjet selected a BAe 146 part for production: a cast magnesium engine thrust control pulley bracket, which suffers from corrosion issues. The bracket is a critical component that redirects engine cables travelling from the cockpit to the pylon connecting the engine to the airframe. “The thrust control pulley bracket was determined by the FAA to be a Class 1 (critical) part, essential for the safety of the aircraft,” explained Jeff Campbell, Director of Maintenance and Manufacturing at Tronosjet Manufacturing. “We knew that additive manufacturing could provide the required strength and that having our new bracket certified by the FAA would validate the use of additive in aerospace production.” Challenge For FAA certification, Tronosjet needed to demonstrate the quality, strength, and reliability of the printed parts. The regulatory body’s material scientists, aerospace engineers, and airworthiness specialists required extensive testing to ensure the bracket’s safety. This included tensile, fatigue, and non-destructive testing (NDT), as well as proof that the titanium alloy and manufacturing process were repeatable and reliable. “Over the years, we have communicated with the FAA many times on different projects, and we understand how it works as a regulatory body,” added Campbell. “This gave us an advantage because we knew what to expect. We knew that we’d need to prove the bracket’s safety using tensile, fatigue, 30 HYDRAULICS & PNEUMATICS January/February 2025 www.hpmag.co.uk Additive Manufacturing takes flight Tronosjet Manufacturing’s use of additive manufacturing (AM) to produce FAA-certified aerospace components highlights the precision and reliability of AM technology. By showcasing a critical titanium part’s superior strength and durability, this case study explores the transformative potential of AM for aerospace applications, with broader implications for hydraulic and pneumatic systems in high-performance environments. H&P reports.
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