Page 30 - World Airnews Magazine May Edition 2021

FEATURE AIRLINES

HOW 3D PRINTING CAN MARKING 30 YEARS IN

REVOLUTIONISE AIRCRAFT ZAMBIAN SKIES

MAINTENANCE AND REPAIR

By Robert Lea

he maintenance of aircraft is a signif-
Ticant challenge for aerospace opera-
tors. The need to quickly repair machines and

get them flightworthy, while also keeping
costs low, is a high-pressure business.
Replacement parts for aging aircraft can

be difficult to source as manufacturers

tend to be reluctant to produce parts for
outmoded, no-longer built, vehicles. This is
especially true if those manufacturers don't purposes. This has been demonstrated by call centre to make or change bookings,
expect to supply such parts more than once the increase in air travel among Zambians and vice versa.
or twice every few years. his year marks 30 years that Profli- in the past decade. The initiative will enable seamless

These demands converge to make a Tght has been fl ying in the Zambian In recent years, the airline has seen the connections on one ticket between the two

method of manufacturing custom reliable and African skies; a record that no other opening of new routes within Zambia and airlines’ networks which include Lusaka,
replacement parts quickly and easily, highly private airline in Zambia’s aviation history in the southern Africa region. From its base Ndola, Livingstone, Mfuwe in Zambia on

desirable. Aircraft operators are beginning in Lusaka, its domestic routes have grown the Proflight network and Plettenberg Bay,

to invest in 3D printing platforms that can has managed to beat. to include Livingstone, Mfuwe, Lower Margate, Johannesburg on the CemAir

provide custom-made devices without the Since 1991, Zambia’s leading airline has Zambezi, Ndola and Solwezi. network in South Africa.
need to commit to the creation of moulds connected Zambia to the southern Africa Throughout the years, Proflight has Having weathered storms and enjoyed

and specific tooling methods. region, linking businesses and reconnecting brought the wonder of air travel to successes over the years, Proflight remains

An example of such a project is the US families and friends. thousands. In 2013, the airline carried optimistic for the future and committed to

Airforce (USAF) and its collaboration with The company says that this platform is up to All of these are necessary for aircraft In 1991, Proflight took to the Zambian over 135,000 passengers, and the number connecting Zambia to the region.

Essentium - a Texas-based provider of 15 times as fast as leading competitors. parts due to frequent exposure to various skies. The airline’s initial goal was to make has been on the rise since then – until the “We are here to stay in order to fulfil our

additive manufacturing solutions. The two In addition to producing parts rapidly, the lubricants, fuels and additives. flying safe, efficient, reliable and friendly impact of COVID-19 which has dramatically mission to ensure essential connectivity

have united to pioneer the production of system can slice down the time needed to for all Zambians and, over the years, most affected travel globally. between Zambia and the region with

advanced additive manufacturing solutions certify parts. The system also is of sufficient This variety is enabled by what the team will agree there is little doubt that the In the company’s early days, its primary a significant economic contribution.

to be deployed over applications such size to allow for the mass production of parts. calls the HSE Hozzle. The oddly named airline has continuously gone above and focus was on tourism-related travel, flying In addition, our vision sees Proflight

as tooling, ground support, and crucially "Essentium demonstrated it has the component is a nozzle that is equipped beyond to achieve its goal. people to national parks, but to reflect the continuing to be a key player in the region’s

maintenance, repair and overhaul (MRO). expertise and capabilities to create parts with both an integrated heating and “Three decades - no small feat” needs of its diverse clientele, today Proflight’s aviation market, while maintaining a

“We're really doing a deep dive into the with consistent replication using the temperature sensing unit - which can heat When the airline was set up by former backbone is business travel, particularly in continuous growth path and innovative

applications and providing materials that Essentium HSE 3D printing platform," materials up to 550⁰C in just three seconds Zambian Airways pilot Tony Irwin (now the mining sector. The on-demand Lusaka- improvement of passenger experience,

- and a sapphire tip that allows for the

can be used across the Air Force and the adds Teipel. "We'll work together to drive extrusion of high-performance materials. Proflight managing director), the company Solwezi route goes to show this. further positioning Zambia as a business

US department of defence,” Elisa Teipel, additive manufacturing technology forward had only one five-seater Beechcraft Baron Its role in the economic growth of the centre and travel hub in the Southern

co-founder and serving chief development and for faster aircraft repairs that massively The system can also be used to create a aircraft. Today, Proflight claims the top spot nation is a key factor in its success, and Africa region,” said Irwin.

officer, Essentium reduce time to deliver parts to keep our variety of moulds and tools in addition to as Zambia’s leading scheduled airline, with it is a position it hopes will come to the As the airline flies into a new decade, its

parts for immediate use, all without the

The project will supply parts for aircraft war fighters ready." need to re-tool. This means an unparalleled a fleet including a 50-seater Bombardier fore again as the world comes out of achievements and milestones in the last
and ground vehicles, focusing on providing The time taken to get aircraft back in the range of creativity and development. CRJ-100 jet, and three 29-seater Jetstream the COVID-19 bubble and revitalises its 30 years tell the story of a true Zambia

support for older aircraft to sustain them, skies will also be vastly reduced because 41 aircraft. economies. success. And as a pioneer in Zambia’s

extend their lifecycle and negate the need the system being developed by the USAF- For the USAF the shift towards the use “Three decades aloft is no small The company has created synergy and aviation industry, Proflight is celebrating

for costly replacements. Essentium collaboration can be deployed of additive manufacturing solutions like feat. We are truly proud to be the first strategic partnerships with other players on the last decade with renewed optimism

The USAF estimates that almost 10000 in situ on the ground at bases or hangers the HSE 3D printer represents a forward- Zambian airline to celebrate this great the market. Proflight signed its first code- for a future of continued growth, while

replacement part requests are delayed each where aircraft are serviced. thinking move away from the dependence achievement,” Irwin said. share agreement with RwandAir in 2015, reflecting on the evolution and needs of

on more traditional supply chains.

year, often because manufacturers can't “And while we have helped pioneer while several interline agreements are in the industry and society.

supply the part. Often these delays cause A WIDER-RANGE OF PRODUCTION “That’s another key breakthrough. It used Zambia towards being a more mobile, travel- place with South African Airlines, Emirates, Despite the negative effects of COVID-19

vital craft to sit in hangers and on runways at MATERIALS to be that you could design things as an savvy generation of flyers, making air travel Ethiopian Airlines and Kenya Airways. Proflight Zambia remains focused on its

critical times. The more creative and custom- Different aircraft parts perform different engineer, but you couldn’t manufacture. more accessible, it is our loyal Proflight More recently, the airline signed a goal of connecting the nation. The airline

based service provided by 3D printing could functions and therefore require a wide With additive, you can design things that customers who are behind our success, and partnership agreement with CemAir commits to stay true to its four values:

help make this a thing of the past. range of physical properties. Fortunately, you can print that you could have never we thank them for all their support.” of South Africa, complementing route safety, reliability, efficiency and friendly

the HSE printer is an open platform, which made before, “ Elisa Teipel, co-founder The past three decades have been service. Q
RAPIDLY PRODUCING PARTS means that it can be adapted to use a wide and serving chief development officer, both rewarding and fulfilling - as well as networks between Zambia and South

Africa, providing customers with a seamless

The team spearheading the USAF-Essentium variety of materials. Essentium. Q challenging. The airline democratised travel experience. Under this partnership, Article courtesy: https://www.

collaboration will develop new materials This includes materials with high the local airspace by giving Zambians the Proflight clients can use CemAir’s ticket themastonline.com/2021/04/15/

and processes using the manufacturer's temperature and chemical resistance and Article courtesy: https://www.azom.com/ opportunity to travel within their country sales desk at OR Tambo International proflight-marks-30-years-in-zambian-

high-speed extrusion 3D printing system. substances with anti-corrosive properties. news.aspx?newsID=55913 and beyond for leisure and business Airport in Johannesburg, as well as CemAir skies/

World Airnews | May 2021 World Airnews | May 2021
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