Author name: info@fkaerospace.com

At Francis Klein Aerospace Equipments, we recently completed a reverse engineering and component repair project using our in-house metal 3D printing capabilities. The project involved a damaged valve body, where a critical outlet portion had broken off and was no longer serviceable through conventional methods like welding or machining. Instead of replacing the entire unit, our team reconstructed and rebuilt only the damaged section using Laser Powder Bed Fusion (LPBF) technology with SS316L material, restoring the valve to full working condition. Component Details The image shows the final restored valve: Application Breakdown Problem:A valve used in industrial fluid handling developed structural damage at one of its nozzle interfaces. The damaged section was not available as a spare, and complete part replacement was expensive. Objective:Use metal 3D printing to restore only the broken portion by: Process Summary  Material Properties – SS316L Key Benefits of This Method  Final Result The repaired valve is now fully functional, passing all mechanical checks and ready for reintegration into the working system. This project is a proof of concept that metal 3D printing can be effectively used for reverse engineering, part restoration, and critical component repair, especially in the aerospace, automotive, and heavy machinery sectors. Summary This application is a successful demonstration of how hybrid manufacturing combining traditional components with additive repair can solve practical challenges in industrial maintenance. With SS316L and precision printing, we’ve shown how metal 3D printing is not just for new parts but also a powerful solution for restoring and upgrading existing components.

At Francis Klein Aerospace Equipments, we recently worked on an exciting prototyping project – the development of an airless wheel tyre using FDM 3D printing. Designed with an internal lattice structure, this tyre offers an innovative solution for puncture-proof, maintenance-free wheels suitable for automotive, robotics, and medical mobility systems. The objective was to validate the structural performance, flexibility, and load-bearing capacity of an airless tyre concept, eliminating the need for traditional rubber inflation systems. Project Overview 3D Printer Details Material Details ⚙️ Printing Parameters Setting Value Layer Height 0.2 mm Nozzle Temperature 250°C Bed Temperature 100°C Print Speed 50 mm/s Support Pattern Grid Print Time 14 hours Post-processing Manual support removal Key Challenges Faced Solutions & Benefits Final Outcome The printed airless wheel tyre maintained its structural shape, flexibility, and internal geometry even after manual support removal. The model was successfully mounted onto a test axle to simulate load-bearing and rolling motion. The performance exceeded expectations in terms of: This successful print demonstrates the value of in-house additive manufacturing for functional prototyping and low-volume part development, especially in industries like mobility systems, automation, and aerospace ground handling equipment. Summary 3D printing the airless tyre prototype enabled our team to create a complex, fully functional concept in a fraction of the time and cost of traditional molding or machining. The project is a strong example of how additive manufacturing supports rapid innovation and design flexibility, helping bridge the gap between CAD and real-world testing.

At Francis Klein Aerospace Equipments, we continuously push the boundaries of innovation in additive manufacturing. In a recent R&D project, our team successfully overcame a critical manufacturing challenge involving a highly intricate polymer component with numerous ventilation holes and complex internal geometries. Project Requirements: The geometry of the component made it extremely difficult to use conventional support structures. Manual removal of internal supports risked damaging the part and compromising tolerances. Specifications of the 3D Printer used – Problem with Using Same Material (ABS) as Support – To overcome these issues, we transitioned to using BVOH (Butenediol Vinyl Alcohol Copolymer) as a water-soluble support material. BVOH prints cleanly alongside ABS and dissolves completely in water, even within complex internal geometries. This change offered several benefits: With this configuration, we achieved a final part that was structurally sound, dimensionally accurate, and visually clean perfectly aligned with the customer’s high-performance expectations. Final Outcome The implementation of BVOH as a soluble support material in our dual-extrusion 3D printing process proved to be a game-changer for this R&D project. By shifting from traditional same-material supports (ABS) to BVOH, we were able to manufacture a highly complex component with zero compromise on quality, precision, or performance. The part featured intricate internal ventilation holes that would have been nearly impossible to clean manually without risking damage. Thanks to the water-soluble nature of BVOH, support removal was effortless and non-invasive. This allowed us to preserve the internal geometry, maintain excellent dimensional accuracy, and deliver a component with a clean, professional finish—all while reducing post-processing time. Key Achievements: Summary This project demonstrates the practical benefits of using BVOH as a soluble support material in FDM printing, especially for components with complex internal structures. It highlights how the right combination of materials and technology ABS for strength and BVOH for clean support removal can overcome traditional manufacturing challenges. we not only met but exceeded the customer’s expectations in terms of quality, accuracy, and efficiency.