Additive Manufacturing Revolutionizing Aerospace with Laser Technology

Related Vendors

FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

The Fraunhofer ILT uses modern laser technologies to address the challenges of aviation. Laser-based processes enable the efficient production or repair of high-performance components.

The aerospace industry is undergoing a profound transformation. Companies face the challenge of drastically shortening development cycles, developing more sustainable technologies, and simultaneously reducing costs. Additionally, advances in satellite technology demand new manufacturing approaches to develop smaller, lighter, and more efficient systems.

While government space programs continue to play a pivotal role, private players like SpaceX, Blue Origin, and Rocket Lab are driving the commercialization of space travel and setting new standards for efficiency and cost-effectiveness – competition has never been greater.

Gallery

In parallel, climate change demands innovative solutions in aviation. The implementation of alternative propulsion systems, the use of sustainable materials, and the desire for zero-emission aircraft are increasing pressure on the industry. It is foreseeable that national and international regulations will impose higher costs on pollutant emissions and enforce stricter requirements for sustainable flying in the future.

This is where the Fraunhofer Institute for Laser Technology ILT comes into play, as state-of-the-art laser technology can address many of these challenges: Laser-based manufacturing and measurement technologies enable the fast, flexible, and resource-efficient production of complex components as well as lighter and more powerful parts. With processes such as Laser Powder Bed Fusion (LPBF) and Laser Material Deposition (LMD), high-performance components for aircraft, carrier systems, and satellites can be efficiently produced or repaired.

Additive Manufacturing for Aerospace

The LPBF basic patent for metallic 3D printing developed at the Fraunhofer ILT forms the foundation for today's prototyping and the production of function-optimized components in aerospace. This drastically shortens development cycles: the journey from CAD model to prototype now takes only a few days, compared to several months in the past—while also reducing costs. Designers gain greater design freedom and can test different variants simultaneously.

"Anywhere that customized, highly complex components are required, additive manufacturing can fully leverage its advantages in terms of flexibility," explains Dr. Tim Lantzsch, head of the Laser Powder Bed Fusion department at Fraunhofer ILT.

In aerospace, additive manufacturing offers enormous possibilities to optimize components while reducing weight and material usage.

Dr. Tim Lantzsch, Head of Laser Powder Bed Fusion at Fraunhofer ILT

A good example of the application of additive manufacturing (AM) at Fraunhofer ILT is the development of LPBF for copper materials. Copper is ideal for components that must withstand extreme thermal loads, such as combustion chambers in rocket engines, due to its high thermal conductivity.

The LPBF team at Fraunhofer ILT has expanded the process limits for copper alloys by specifically using green laser radiation to process GRCop42 (CuCrNb). This enables the production of high-density, thin-walled structures with optimized thermal management—a crucial advantage for aerospace applications, which benefit from more durable components with higher efficiency and reduced manufacturing costs.

LMD is another established AM process for manufacturing components with high precision and optimal material properties. In the ENLIGHTEN project (European Initiative for Low cost, Innovative & Green High Thrust Engine), it enables the high-productivity production of components with optimized topology, reduced weight, and maximum durability. "What makes it special is that through the diverse capabilities of LMD technology, we drastically improve the speed and cost-effectiveness of producing new generations of rocket nozzles. The design under investigation, apart from its large build volume, features exceptionally delicate and thin-walled cooling channels, which can only be realized with great effort using conventional manufacturing methods," explains Dr. Thomas Schopphoven, Head of the Laser Material Deposition Department at Fraunhofer ILT.

Another focus is on the production of structural components for aircraft with high strength and reduced weight. LPBF enables the manufacturing of lightweight components that enhance the efficiency of modern aircraft. Additionally, AM contributes to the efficient repair and maintenance of aerospace components. With LMD, damaged parts can be specifically renewed—a crucial step toward streamlined supply chains, sustainability, and cost reduction.