Renishaw Helps Tronosjet Manufacturing Achieve FAA Certification

Overview

Tronosjet Manufacturing, a Canadian company specializing in aircraft leasing, modification, and maintenance, sought to enhance its additive manufacturing (AM) capabilities to produce certified metallic aerospace parts. To achieve this, they partnered with Renishaw, a global engineering technologies company known for its advanced manufacturing systems. Tronosjet aimed to produce various aircraft components, including a critical engine thrust control pulley bracket, which is one of the first additively manufactured metallic parts to receive certification from the Federal Aviation Administration (FAA) under its Parts Manufacturer Approval (PMA) scheme.

Founded in 2001, Tronosjet established its advanced manufacturing division in 2016 to leverage AM technology for producing aerospace components. The company’s manufacturing facility is recognized as an Aerospace Manufacturing Organisation under Transport Canada 561 and holds AS9100 approval, ensuring adherence to industry standards for quality assurance and risk management in aviation.

The thrust control pulley bracket, traditionally made from magnesium, was selected for AM production due to its susceptibility to corrosion. This component is critical for aircraft safety, as it holds a pulley that redirects engine cables from the cockpit to the engine pylon. The FAA classified the bracket as a Class 1 (critical) part, necessitating rigorous testing to demonstrate its strength and reliability.

Tronosjet faced the challenge of proving the quality of AM parts to the FAA, which involved extensive non-destructive testing (NDT), static, functional, and destructive testing. The company opted to print the bracket using aerospace-grade Ti-6Al-4V titanium alloy, which demonstrated superior performance compared to the original magnesium version. The printed bracket exhibited five times the strength of the cast version, withstanding loads over 22,000 lb, while the original broke at just 4,000 lb. This significant improvement in tensile strength helped convince regulators of the viability of AM in aerospace applications.

With the successful demonstration of the bracket's strength, safety, and quality, Tronosjet achieved FAA certification, allowing them to produce and supply the component to customers. This accomplishment not only validates the use of additive manufacturing in aerospace but also provides Tronosjet with a competitive edge in the industry. The partnership with Renishaw was crucial in this journey, as their engineering expertise and advanced AM systems played a vital role in achieving certification.