Key Takeaways
- Additive manufacturing (AM) is emerging as a promising method to produce EWIS components.
- Modern printers can now produce high-quality connector bodies that previously required custom injection molding.
- AM introduces many process variables that must be tightly controlled and validated.
Introduction
The value of AM for EWIS
Electrical Wiring Interconnection System (EWIS) is the amalgamation of wires, cables, connectors, and support hardware that connect aircraft components. Additive manufacturing opens new possibilities for complex, low-volume EWIS hardware without expensive tooling.
EWIS parts suited for AM
Connectors, backshells, clamps, and brackets benefit from AM’s geometry freedom. TE Connectivity’s D369 connector bodies were printed in flame-retardant polymer with ±0.002 inch accuracy, proving aerospace-grade precision.
FAA perspective
The FAA requires applicants to show how they will consistently meet requirements. Existing regulations still apply; policy memos and ACs add scrutiny for AM to ensure rigorous qualification.
Process controls
Laser powder bed fusion can involve 100+ parameters. FAA AC 33.15-3 stresses identifying critical variables and monitoring them within defined ranges. FAA Order 8110.4C requires detailed process specifications covering equipment, environment, inspection, and acceptance criteria.
Conclusion
Additive manufacturing for EWIS is real today. Connector housings, wire clamps, and custom hardware are already flying. Companies must still prove materials, safety, and repeatable quality. Lectromec’s ISO 17025 lab is ready to test AM and conventional parts. Contact us to discuss your program.
