Research Program Using Additive Manufacturing to Create More Sustainable Aircraft Engines

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The [ˈskai]-lab research program combines quality control, structural monitoring and operational safety of additively manufactured components for electrified aircraft engines with the aim of making aviation more sustainable in the future.

New and lightweight drive technologies are needed to reduce emissions in aviation. Additive manufacturing plays a key role here, as it enables complex and weight-optimized components that are crucial for electric drive systems. This is precisely where the ['skai]-lab cooperation comes in by strategically combining the expertise of additive manufacturing (BAM, BTU) and non-destructive testing (BAM) with the application requirements for innovative drive concepts and components in aviation (DLR, BTU).
The focus is on additively manufactured components for electric drive systems - from electric motors and gearboxes to heat exchangers. By combining state-of-the-art manufacturing technologies with non-destructive testing methods and data-driven process optimization, the aim is to create high-performance, durable and resource-efficient components.

"With ['skai]-lab, we are setting new standards for 3D printing in aviation. Our goal is to jointly develop innovative materials and manufacturing processes that not only meet the highest quality and safety standards, but also contribute to low-emission aviation through more efficient use of resources," explains BAM President Prof. Dr. Ulrich Panne.

Acquiring Interdisciplinary Skills

The core of the program is a qualification program for doctoral students that aims to provide a comprehensive understanding of the entire value chain—from production and quality control to regulatory framework conditions. This is supplemented by soft skills courses, summer schools and international research stays. The aim is to train highly qualified experts who will take on a pioneering role in science, industry and the public sector in the future and bring with them precisely the skills that industry needs for technological change. BTU President Prof. Dr. Gesine Grande: "The cooperation in the ['skai]-lab offers our doctoral students the unique opportunity to acquire interdisciplinary skills in manufacturing technologies and quality assurance in order to actively contribute to sustainable aviation of the future."

Networking And International Visibility

['skai]-lab is closely integrated into the international research network of DLR, BAM and BTU. The doctoral students will benefit from an intensive interdisciplinary exchange, comprehensive scientific expertise and access to state-of-the-art research infrastructure. Cooperation with leading companies such as Airbus and MTU as well as support from national professional associations and an external advisory board will build a bridge to industrial practice, according to the cooperation. "The close cooperation between the research institutions with a focus on future industrial needs in the ['skai]-lab creates a unique environment to advance the use of electric drive technologies for aviation and thus significantly reduce CO₂ emissions," emphasizes Prof. Dr. Lars Enghardt, Director of the DLR Institute of Electrified Aircraft Propulsion Systems and Head of the BTU department of the same name.

Completion of First Doctorates By 2030

The program will initially start with nine doctoral projects, three at each participating research institution. They cover the entire process chain: from the development of additively manufactured heat exchangers and waveguide windings for e-machines to data-driven optimization using Physics-Informed Neural Networks (PINN) and robust Structural Health Monitoring (SHM) methods. Particular attention is paid to sustainability, resource efficiency and reducing CO₂ emissions. The first promotions should be completed by 2030. In this way, ['skai]-lab aims to create a basis for new scientific findings, the further development of innovative technologies and the sustainable transfer of knowledge. At the same time, the program will contribute to the training of highly qualified scientists.

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