Metal 3D printing can help aerospace companies overcome common pain points, create new value for customers, and bring new strengths to existing technologies. Gaylord Klammt, Metal 3D Printing Director at Materialise, explains why it’s an important opportunity for the industry, and how our Metal Competence Center can help you take advantage of it.
If you’re familiar with the basics of metal 3D printing, you likely already know its benefits. Many of them feel tailor-made for aerospace: design freedom, lightweighting, a buy-tofly ratio that traditional manufacturing techniques can’t match, and short lead times, to name a few. Likewise, the ideal applications match up well. Lightweight structural brackets, complex ducts — essentially, any time your project involves complexity, weight reduction, or part consolidation, additive manufacturing can deliver.
The metal 3D printing opportunity
These characteristics make additive manufacturing a pivotal solution for decision-makers in the industry, especially those facing common challenges like long lead times for spare parts, obsolete tooling, slow, complex supply chains, and high-volume, low-mix demand. If adopted correctly, additive manufacturing enables local, on-demand production and supply chain resilience, soothing those pain points and creating a competitive advantage.
And that’s really just the tip of the iceberg. Beyond spare parts, aerospace companies can reap the rewards of redesigning existing components — benefits like extended life times, improved performance, reduced aircraft downtime, and value-added repair or upgrade solutions. Together, those benefits have a positive impact on both economic and environmental sustainability, too. Lighter parts burn less fuel. 3D-printed parts consume less material. Producing locally limits transport emissions and improves supply chain security. Longer-lasting, repairable parts reduce waste and downtime. As governments and the aerospace industry itself begin to prioritize sustainability goals, metal 3D printing can quickly become an invaluable tool.
Metal 3D printing today
With all that in mind, it’s not surprising that more and more companies have adopted the technology in recent times. Currently, they’re primarily focusing on low-risk, low-criticality applications, like spare parts, tooling, and support equipment.
After all, the technology is still developing. Advancement in this industry runs on data, so while the most carefully regulated parts may seem out of reach right now, I believe even that will change in the future. In fact, it is changing — engineers are getting more experience and gathering more data. Different parts are coming. Big OEMs are using it. They’re creating their own confidence with metal 3D printing.
As the technology matures, we’ll likely see those applications evolve to include flight-critical applications. For that to happen, companies across the industry need to have confidence in the technology, backed by data from specimen tests, standardized qualification approaches, stable processes, and digital traceability.
How can you take advantage of metal 3D printing?
I’d summarize the journey into five main tasks or milestones:
1. Identify suitable applications, like those I mentioned above
2. Build your internal AM competence – bring experience in-house, try, test, and gather data
3. Work with experienced partners
4. Develop qualification and approval pathways
5. Integrate 3D printing into your existing qualification pathways
You’ll quickly notice that this list includes both technological and cultural points. In my opinion, each is equally important — without the right mindset, your progress will be limited. And that goes both ways; as point 5 suggests, it’s not all-or-nothing with metal 3D printing. You need the best of both worlds.
What do I mean by that? What I like, and strongly encourage, is to always have an open mindset. Consider both traditional and additive manufacturing, combine their strengths, get everybody on the same page, and you’ll deliver the best results for your customers.
Your partner for additive manufacturing in aerospace At Materialise, we have a proven history of driving the growth of additive manufacturing, and our Metal Competence Center is at the heart of it all. When we talk about our site in Bremen, we often refer to it as our hub of industrial-grade metal additive manufacturing. Our customers can expect certified production, engineering expertise, in-depth knowledge of 3D printing materials, and post-processing facilities, all under one roof. It’s proof that we’re much more than just a manufacturer.
