Hexagon and Nikon SLM Solutions achieve 75% weight reduction in Airbus A330 Fuel Air Separator

Hexagon AB’s Manufacturing Intelligence division and Nikon SLM Solutions have collaborated to redesign a large, fabricated aircraft fuel system component using the design freedom of Additive Manufacturing. Using Hexagon’s simulation-led Design for Additive Manufacturing (DfAM) toolchain and Nikon SLM Solutions’ advanced multi-laser metal Additive Manufacturing technology achieved significant lightweighting, part consolidation and precise geometric tolerances.

Airbus Operations used the technology from its partners to redesign a Fuel Air Separator – a component that feeds the Airbus A330’s Auxiliary Power Unit (APU). The combination of Hexagon’s software and Nikon SLM Solutions’ Additive Manufacturing technology has enabled the production of the simplified, more efficient AM A330 Fuel Air Separator prototype. The re-design achieved a 75% weight reduction from 35kg to less than 8.8kg, setting a new precedent for the use of Additive Manufacturing and simulation-driven design in the aerospace industry.

The fuel-air separator is a large, complex component that removes air from the APU fuel feed system, ensuring the APU can power essential aircraft systems when the main engines are off. The conventional part is fabricated from more than 30 individual components that require manual welding and assembly. This process is labour-intensive, which results in long lead times, and limits the potential for design improvements.

Airbus Operations and Nikon SLM Solutions initiated the research case study to optimise the production and performance of the air separator, creating an innovative process that used Nikon SLM’s latest NXG XII 600 system – a large-format, multi-laser Additive Manufacturing machine – to simplify manufacturing, reduce lead times and streamline installation.

Simulation-driven redesign unlocks design freedom

The team called upon Hexagon to redesign the part using a DfAM workflow to maximise the potential of the advanced Additive Manufacturing system. Using Hexagon’s MSC Apex Generative Design software, they consolidated over 30 individual components into a single lightweight part that met all necessary structural and performance standards. Hexagon’s Simufact simulation tools were then used to optimise the manufacturing process and predict part deformation, ensuring that precise geometric tolerances were maintained. Global tolerances were controlled to +/- 5 mm, with critical functional surfaces refined to +/- 5 mm to ensure seamless compatibility with the aircraft’s fuel system.

Simulation-driven design allowed for part optimisation while adhering to the stringent aerospace regulatory requirements. The Additive Manufacturing technology employed significantly reduced lead time by combining multiple manual processes and reducing production time. The large part was produced in just 68 hours, using optimised build data from hexagon’s AMSTUDIO build preparation software to fully utilise the NXG XII 600 powder bed fusion AM machine and maintain precise geometric accuracy.

Advanced manufacturing drives sustainability innovation

Lower fuel consumption is due to reduced part weight, decreased manufacturing lead time, and enhanced efficiency gained through the manufacturing process.

This project demonstrates the power of combining Additive Manufacturing with simulation-driven design, and Airbus is well-positioned to expand these technologies in future aircraft designs.

If you are attending Formnext Hexagon can be found at Hall 12, Stand B21 and Nikon SLM Solutions at Hall 12.0 B119.

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