Utilizing Selective Laser Sintering For Production Fabrication of Peculiar Support Equipment

Traditionally, helicopter peculiar support equipment is designed, developed, and fabricated using conventional methods, primarily with metallic materials. Specifically, component repair and overhaul tools containing unique, complex features (e.g. internal involute splines) are fabricated using conventional broaching, machining, or electrical discharge machining (EDM) techniques. These techniques combined with the low volume production and acquisition of these products, result in high cost and long lead times. As an alternative, Selective Laser Sintering (SLS), the process of using 3D CAD models to "grow" parts using a laser to sinter powdered material, can be utilized with the primary benefits being inherent cost savings and lead time reductions. This process also facilitates the ability to develop unique, innovative, and simpler tools that would have been impractical or impossible to fabricate using conventional methods. Feasibility, proofing, and practical implementations are the focus of this paper.