Landing-Gear Industrial Breakthroughs "I-Break" will develop and manufacture major components with innovative techniques such as powder hot isostatic pressing, additive manufacture and composites. The Landing-Gear major components; main fitting, sliding piston and actuation are drivers of the aircraft key competitiveness factors; * Development time and cost (NRC), * Recurring cost (RC) * Industrial environmental impact Manufacture has changed little over time, relying on large forgings with no UK footprint. I-Break will develop solutions to be applied on the Next-Generation and Zero Emissions aircraft ready for exploitation. Innovative industrial means are essential to secure breakthrough improvements in the key competitiveness factors.

The project will take Powder Metallurgy Hot Isostatic Press (PM/HIP) through the commercialisation "valley of death" to complete Technology Readiness Levels (TRL) 4 through 6 critical process criteria, as set by AIRBUS. PM/HIP is a Near Net Shape technology and provides a method for manufacturing large complex designs, reduces wasted material by drastically reducing buy-to-fly ratios & excessive machining times compared to classical processes such as closed die forgings. Under this project it also attempts to achieve higher strength and greater ductility than classical forged parts to further reduce aircraft weight & allow the introduction of thinner cross sections to survive the same component loads. Freedom to design new part geometry could also reduce the number of parts required by removing the need for fasteners or welding by making combined single piece components. Assessment of new Generic Material or Technology characterisation through coupon testing in representative conditions to prove key characteristics vs targeted will be targeted alongside subcomponent demonstration in a near industrial environment shall be undertaken. Demonstration activities is key in providing the feasibility to achieve sub-2:1 buy to fly before approaching full scale demonstration in an industrial environment is required for TRL6\. The project will be delivered by lead partner Maher (capsule design patent holders, titanium additive manufacturing expertise), the University of Sheffield's (UoS) Nuclear Advanced and Advanced Manufacturing Research Centres (NAMRC/AMRC, HIP optimisation, landing gear consultation, Discrete Event Simulation, waterjet capsule release), Westmoreland (WMTR, large-scale fatigue testing), Replicast (capsule manufacture), EDR Medeso (capsule design and simulation), and PES performance (component scanning and inspection).