De Havilland Aircraft of Canada (DHC) is a global leader in turboprop and special-mission aircraft, renowned for developing robust and reliable planes that operate in some of the world’s harshest environments. Since its founding in 1928, DHC has played a vital role in connecting rural and urban communities through aviation. With facilities in Victoria, Toronto and Calgary, DHC’s historic location is now the current-day home of Centennial College’s Downsview Campus and its Aerospace Manufacturing and Maintenance Programs.
Since August 2023, Centennial Innovates – the Applied Research, Innovation and Entrepreneurship department of Centennial College – and DHC have been collaborating together on a project titled "Emergency Exit Latch Parts Optimization using Additive Manufacturing (AM)." This project aims to redesign aircraft exit latch components utilizing topological optimization methodology, a mathematical method which optimizes the material layout and distribution within a given design space. The project’s main purposes are to reduce three aspects: the components’ total weight, manufacturing time, and number of parts that currently constitute the latch. Additionally, the project scope also included using additive manufacturing (3D printing) to print the newly designed parts as well as performing tensile, compressive, and flexural testing on the parts. These results would be crucial for the design and development of an innovation solution that would consider new technologies and materials.
The project featured an important partnership with Canadore College’s Innovation Centre for Advanced Manufacturing and Prototyping (ICAMP). Located in North Bay, Ontario, ICAMP is a 13,300 sq. ft. innovation centre offering industrial laboratory and design space. They provide a variety of advanced manufacturing services, including but not limited to 3D printing in a variety of metals, plastics and composites using EOS, Stratasys and Markforged equipment, upgraded waterjet cutting, and 3D laser printing using Glowforge Pro. Because the exit latch parts needed to be printed in a specific material – Al10SiMg, a lightweight, high-strength aluminum alloy – ICAMP’s partnership in printing and machining the parts was crucial to allow for their testing in the project’s later stages.
As with any Centennial Innovates applied research project, student researchers worked directly with industry partner DHC as well as Canadore College and were involved at every stage, from the exit latch parts’ design and optimization to its 3D printing and testing. Throughout the two-year project, five student researchers were engaged from various programs within Centennial’s School of Engineering Technology and Applied Science (SETAS). The team was initially formed with two students from the Mechanical Engineering Technology program—Diego Alexis Herrera and Tulio Sousa—until their graduation in mid-2024, after which three new team members from the Aerospace Manufacturing Engineering Technology program joined: Bipul Jha, Adnan Sheikh, and Herick Brasil dos Santos.
"The Topology Optimization for Aerospace Additive Manufacturing research project with Centennial Innovates and DeHavilland Canada has been an incredible journey," remarked Professor Wladimir Figueiredo, faculty member at SETAS’s Advanced Manufacturing and Automation Technology (AMAT) department teaching Industrial Mechanical Engineering Technology. As the project’s Principal Investigator, he leads the team and provides technical expertise and guidance. "This project represents a promising step toward sustainable engineering within advanced manufacturing, demonstrating that the dedication and ingenuity of many scientists are creating tangible advancements in technology for both local and global communities." Professor Figueiredo also expressed the profound reward in watching his student researcher team apply advanced concepts in material science, mechanical design, quality assurance and data analysis, as well as hone their soft skills such as time and project management. "I am immensely proud of my team of student researchers and project managers who have tackled complex challenges in logistics, design, manufacturing, and analysis. This project has also pushed me to stay current with the latest technologies and keep my technical knowledge in applied science and research sharp. It has strengthened my managerial skills and reaffirmed the importance of learner-centered education. I have no doubt this team consists of highly skilled, dedicated, and courageous professionals who are ready to make significant contributions to the field."
The Centennial Innovates team worked both online and met regularly in person to collaborate on project tasks. "I enjoyed working remotely," shared Bipul Jha, "but I greatly enjoyed working in the Quality Control Lab as well as the Landing Gear Innovation Lab. I gained soft skills that include technical report writing, team management, as well as communication skills. The technical skills I learned are Ansys simulations, MTS testing, and 3D printing, which I am very proud of and will be highly useful in my career."
Adnan Sheik was the main team member seeking and contacting external suppliers, and had an important role coordinating with Canadore College throughout the acquisition of ICAMP’s services. "My primary responsibilities included coordinating with external manufacturers for 3D-printed components, designing fixtures, and conducting destructive testing to validate our designs," said the student researcher. "This role allowed me to bridge our team’s needs with external resources, ensuring precision and quality in our testing process."
Tulio Sousa described some of the tasks involved in the project. "My role was first to do a theorical research using the resources from the College to understand the resistance of materials and technologies on additive manufacturing. I also went through training on software, learning how to use topology optimization to create a new design for the product." He explained. "Then, with the research and training, the activities were related to developing the new design, running Finite Element Analysis (FEA) cases, and preparing documentation to present at weekly meetings where we would discuss advancements and possible solutions for the issues encountered during the research. We also have opportunities to go to manufacturing shows to acquire more knowledge, and use additive manufacturing technologies to print prototypes."
The various technical and soft skills that student researchers gain during projects like these are invaluable. "My experience was fantastic…a great opportunity to apply the knowledge we acquired in our classes in a real-world environment." expressed Herick dos Santos. "The team was very organized on dividing tasks and attending to weekly meetings…we did number of things completely related to the course I am studying. It is a fantastic opportunity to have more experience on the professional environment and also make great and valuable industry connections." Student researcher Diego Herrera echoed Herick’s enthusiasm. "My recommendation would be not to hesitate; this is the best place to grow, learn, and connect with highly skilled professionals. Don't view it merely as a job; see it as an opportunity that can open many doors down the line. You learn a lot, and there is a complete immersion in the professional world. Don't be afraid to make mistakes; give it a try, and you won’t regret it."
There are many ways to apply for student researcher positions at Centennial Innovates. For example, Diego Herrera, who worked for this project for 11 months, came across the opportunity on LinkedIn. "One day, I was reviewing my LinkedIn account when my wife was the first to see the job posting. She sent it to me, saying, 'Look at this job opportunity at the college where you study! It's also related to what you've been doing for a long time in your job and what you studied in Colombia. Why not give it a try?' That same day, I applied, and two weeks later, I had the opportunity to work with this wonderful team." For Bipul Jha, he heard about the position through a professor during his classes. Herick Santos found the open position on the HireCentennial platform.
For any Centennial College students looking for a new experience, Adnan has given the following advice: "Embrace a positive outlook and continually advance your studies while actively seeking new opportunities. Remember that no opportunity is too small; each one can lead to significant growth and development."
This project is concluding by the end of November 2024 with the delivery of a complete technical report including data analysis, recommendations for the industry partner and research findings alongside the 3D printed parts for DHC's display.