Any power-driven transportation vehicle is a complex system, composed of numerous assemblies, sub-assemblies and components encompassing various mechanical, structural, electrical and computer systems for its operation. Depending on the mode of transportation, be it land vehicles, sea vessels, aircraft or spacecraft, each application has its own set of challenges in its development and production. The need for improved part performance along with reduced manufacturing cost is a driver for technological innovations in both design and manufacturing processes. This paper focuses on an innovative way of achieving cost and performance improvements for structural assemblies using Additive Manufacturing (AM) in a hybrid approach. The hybrid AM process discussed in this paper is a combination of AM with existing manufacturing processes in the fabrication of a single part or assembly. The discussion of this approach will be in the context of engine components and a variety of fastening applications within rotary aircraft.
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