Textron
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Client
Textron
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Industry
Aerospace
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Capability
3D Printing
Reduced Production Time 72%
99% Accuracy via Expert DFAM
Completed 4 Operations In-House
Fathom Simplifies Development of Aerospace Test Device
Fathom used additive technology to build a lightweight, hand-held testing device for the aviation industry. This complex part required tight tolerances, multiple inserts and extensive post-processing. All finishing and assembly was done under one roof.
The Problem
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The customer asked Fathom to build a complex housing to which multiple instruments and electronics would be attached for a handheld ground testing device. Several surfaces of this part required tight tolerances, post-machining and installation of multiple threaded inserts.
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The customer was also looking for assistance in lightweighting this part to improve its ergonomics. In addition, the housing also needed to be finished with an EMI coating to shield the device’s sensitive instruments and signals from interference.
The Solution
DFAM Analysis // Fathom’s experienced engineering team performed a detailed DFAM analysis, which uncovered several opportunities for improvement and helped prevent hidden problems during production. The design modifications suggested by the Fathom team included reducing the weight of the part by 10% and the cost of production by 15%.
These housings were 3D printed to exact tolerances using SLS made of glass-filled nylon. This material provides excellent structural rigidity and impact resistance. Several of the part’s surfaces were post-machined to meet the customer’s requirements. Next, the Fathom production team sanded, primed and painted the housings with a high-gloss, bright red finish. An EMI coating was then applied. Finally, the Fathom team installed multiple threaded inserts for 10/32-in. screws, to which instruments and electronics were attached. Fathom also did some assembly work on these devices.
The Results
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Fathom provided the customer with a turnkey solution that included printing, machining, painting, assembly and inspection and was 99% accurate to quote.
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Fathom was able to complete all four operations in-house, saving Textron several weeks compared to its previous supplier and their external partners.
Reduced Production Time 72%
99% Accuracy via Expert DFAM
