Additive Manufacturing for Aerospace: 7 Applications that Prove AM is a Powerful Tool for Aerospace Industry
24 Sep 2024 
Additive manufacturing (AM), simply known as 3D printing, is now used by many manufacturing industries, particularly aerospace, to revolutionise how they manufacture aircraft components. This innovative tool uses CAD or computer-aided design and 3D object scanners to create precise geometric shapes.
This new process differs from traditional moulding or machining because it can make more complex details inside through a layer-by-layer process. It also allows aerospace manufacturers to build aircraft parts with lighter components, better design flexibility, cost savings, and faster manufacturing times.
In this article, explore further the seven real-world applications where AM is revolutionising aerospace so you can know how or if this tool can help your business.
Lightweight Components
Weight is an important consideration when designing aircraft engines and components, and using AM allows manufacturers to create lightweight yet robust pieces. This innovative technology uses alternative materials such as titanium, plastic, and other specialised composites.
Additive manufacturing has been helpful for the aerospace industry to save operational expenses and fuel consumption. An excellent example of this is the Boeing 777x. It’s one of the world’s most efficient twin-engine aircraft, using GE9X engines with more than 300 3D-printed parts.
Rapid Prototyping for Aerospace Parts
Manufacturing aerospace parts has always been tedious as it needs multiple processes, bonding, and finishing. However, with the integration of additive manufacturing, the prototyping process is much faster and allows engineers to test and refine part designs quickly.
For instance, Airbus, a European sustainable aerospace company, has been using a 3D printer to rapidly prototype full-scale aircraft components like panels and linings. This helps cut outsource lead times, reduce costs, and streamline design iteration processes.
Creating Complex Geometries
As previously mentioned, additive manufacturing shines in its ability to produce complex shapes or geometries, which would have been impossible in traditional moulding processes.
This AM feature has allowed aerospace companies to design parts with intricate internal structures–like the honeycomb shape for better visualisation. Creating these detailed structures is vital to improving aircraft’s performance and weight reduction.
Reducing Material Waste
Additive manufacturing is a solution many manufacturers have found to reduce waste materials in production, which has been effective as this technique only uses the exact amount needed to build aerospace parts.
NASA, for instance, has been a pioneer in applying AM in its spacecraft component manufacturing. This effort has helped the agency downsize production costs and significantly contribute to its overall sustainability efforts.
Part Consolidation
In traditional moulding or machining, manufacturers mould little parts before assembling the component as a whole. Additive manufacturing simplifies this step as the tool consolidates multiple parts to reduce the number of joints and assemblies and to save time and resources.
In 2012, GE Aviation used AM to reduce the number of parts in jet engine fuel nozzles from 20 pieces to one. This innovation led to a 25% weight reduction and less assembly time.
Improving Maintenance, Repair, and Overhaul (MRO)
Efficient and fast maintenance and repair are crucial, especially in the aerospace industry. This is why additive manufacturing services enable “on-demand production” of replacement parts or manufacturing a single component as needed rather than creating bulk spare parts upfront.
With AM, aerospace companies can also 3D print the needed parts in remote locations, ensuring quick repairs and avoiding shipment hassle.
Customised Tooling
Another critical benefit of additive manufacturing is allowing engineers and designers to explore or experiment with custom parts or tooling, which they can use in specific or unique projects.
With additive manufacturing in place, aerospace companies can freely design and produce tools that suit their needs faster, with lower costs and more efficiency.
Unlocking the Future of Aerospace with Additive Manufacturing
Aside from the seven benefits and applications presented above, additive manufacturing still has a lot in store for many industries. The technology is only widely used in aerospace, so its maximum potential is yet to be explored.
As the technology continues to evolve, integrating AM into your operations is critical to keeping a competitive advantage against other aerospace manufacturers that have already shifted ways.
If you’re in the same industry or other businesses where you can integrate AM, consult with the best engineering solution provider, like AECSS.
We specialise in providing state-of-the-art end-to-end additive manufacturing services tailored specifically to your business needs. Contact us today for customised AM solutions to equip your business for the future.
