THE AVIO AERO

PEOPLE’S MAGAZINE

Avio Aero is one of the first aerospace companies to add to the scope of work of the already existing Production Organization Approved, approved by ENAC (Italian Civil Aviation Authority), the production of propulsion system components through additive manufacturing, specifically those made with Direct Metal Laser Melting (DMLM) technology at the Brindisi plant.

Starting in 2023, in line with the company's strategy, the company has embarked on the path with ENAC to extend its capability list, which is the specific list of types of processes, procedures, and components that the organization is authorized to produce or maintain, in compliance with the regulations and certifications required by the competent aviation authorities. Thanks to the developed and implemented production and quality control processes, the supervision, and continuous collaboration with ENAC, it has been possible to include additive technology in the Scope Of Work of the POA, in compliance with EU regulation 748/2012, and thus include the produced Part Numbers in the Capability List.

Avio Aero boasts extensive experience in the development and application of Additive Manufacturing processes, particularly with the Powder Bed Melting method, which involves the deposition of layers of metal powder on a work surface where they are melted, layer by layer. Over the years, the company has industrialized Electron Beam Melting (EBM) technologies, which use an electron beam to melt layers of metal powder, and Direct Metal Laser Melting (DMLM), which uses a laser, and these are used to create highly technological products present in various engines used worldwide.

But what does this mean exactly?

Leveraging the technical expertise and experience gained over the years, Avio Aero has developed internal process and personnel qualification procedures and specifications, proposing and agreeing them with the Italian board of non-destructive controls (ITANDTB) for the verification and control of components produced with additive technology using the tomographic technique. This technique involves the computer reconstruction of two-dimensional radiographic images into a three-dimensional volume more suitable for inspecting complex geometries that include integrated air/fuel ducts.

The success of this achievement, with the recognition obtained from ENAC in the POA certificate, is undoubtedly the result of the work of an extensive cross-functional team. This group includes, among others, Sara Guelfo, who developed and defined the tomographic standards and qualified the new control process and personnel; Michela Castellano, who followed the development and industrialization of the production process ensuring the necessary quality and becoming Certifying Staff approved for additive technology; and Paola Giordano, who coordinated all certification activities with the national authority and ensured independent oversight of the internal process and at suppliers.

This achievement is an important milestone for Avio Aero, strengthening its position in the market and its ability to offer safe, reliable, and cutting-edge products to all its customers.