Apr 3, 2019 | By Thomas

The cabin and avionics specialist Diehl Aviation announced that it has delivered the largest, fully 3D-printed part for passenger aircraft to date. The part in question is a Curtain Comfort Header – a complex enclosure for the curtain rail for installation on a Qatar Airways Airbus A350 XWB. The module, made using the fused deposition modeling (FDM) technique, measures 1,140 x 720 x 240mm.

Qatar Airways will be the first airline to use the 3D-printed Curtain Comfort Header on board. The project took 12 months from initial concept to EASA certification and delivery. 3D printing helps Diehl Aviation solve several problems. One complete Curtain Comfort Header is comprised of up to 12 component parts. These modules were usually formed from numerous layers of laminated fiberglass, each of which required its own individual, complex aluminum tool. Incorporating further functions into the module, such as the integration of cable channels, emergency escape route signage, or specialized retaining clips presented further complexity. However, when produced using 3D printing, all the component parts can be produced by a 3D printer and glued together when complete.

Curtain Comfort Header Shark fin. Image: Diehl

Given these many advantages, Diehl Aviation will now only produce Curtain Comfort Headers for the A350 XWB using 3D printing method. Furthermore the parts themselves require less reworks and can easily be removed for repairs or replacement, contributing to even shorter waiting times during repair works. Also, the modules can easily been customized for retrofit solutions. Meanwhile passengers benefit from the precision-made parts that lead to dampen noise and allow better integration in the cabin.

Curtain Comfort Header Exit. Image: Diehl

Diehl Aviation is a division of Diehl Stiftung & Co. KG and combines all aviation activities of Diehl Group under one roof. The company is a leading system supplier of aircraft system and cabin solutions and currently has around 6,000 employees. Its clients include Airbus (both airplanes and helicopters), Boeing, Bombardier and Embraer, as well as airlines and operators of commercial and business aircraft.

Diehl Aviation will be exhibiting the Curtain Comfort Header at its booth 7D20 at this year’s Aircraft Interiors Expo in Hamburg.



Posted in 3D Printing Application



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