Challenge
A major aero-engine OEM faced significant manufacturing inefficiencies with their existing bearing housing design. The component featured 48 welded cast vanes, resulting in an unnecessarily complex assembly process that increased production costs and time. In an industry where the quality of every component affects operational efficiency, this suboptimal design needed urgent optimization.
Solution
Quest Global delivered an optimized bearing housing design that:
Implemented single-piece casting architecture to replace the complex 48-vane assembly
Validated structural integrity through comprehensive analysis aligned with OEM standards
Developed complete design documentation, including stress analysis and engineering drawings
Reduced aerodynamic wind steps in the annulus to enhance performance
Created manufacturing guidelines to ensure consistent production quality
Results – at a glance
Achieved 50% reduction in manufacturing costs
Decreased component weight by 23%
Improved aircraft fuel efficiency through enhanced aerodynamics
Met all redesign requirements 100% on-time and on-budget
Delivered all redesign requirements on schedule and within budget
Provided complete documentation package, including 3D models, stress reports, and manufacturing specifications
