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Additive Manufacturing: An Aerospace Revolution

You may already know how 3D printing allows the rapid fabrication of mechanical parts and spares in industries. It enables swift prototype creation and iteration and the production of pieces in any number or style without wasting too many resources. In addition, it focuses on decreasing load, reinforcing materials, and optimizing design.

Advantages of Additive Manufacturing

Instead of assembling several little pieces for a single element, additive manufacturing allows a single, huge element to be constructed as a solitary group from the base. As a result, producers will be able to decrease wastages, cost, and complexity.

Another important advantage of AM techniques may indeed outweigh all other systems combined. When vintage airframes are no longer manufactured, the producer is often lawfully compelled to discard the molds and machinery, especially in military agreements. This is a constitutional requirement that must be met.

Regrettably, mechanical members wear down as planes exceed benchmarks. This problem can be solved with 3d printers. Identical duplicates of internal parts can now be made on a demand basis. The timeframe will also be unthinkable because such modification doesn’t necessitate costly tooling and casting assembly.


The aviation sector contains divisions designing, producing, implementing, and supporting aircraft and spacecraft for various corporate, manufacturing, and defense uses. As an early adopter of additive manufacturing the aviation industry continues a strong push into developing this innovation for both terminal parts and testing. 3D printing is used by airlines to counteract sourcing bottlenecks, minimize storage space, and eliminate byproducts generated by conventional manufacturing techniques. Rapidly manufacturing airplane parts on-demand preserves much space, human resources, and budget.

Since heaviness impacts an aircraft’s cargo, fuel intake, exhaust, performance, and even stability, decreasing weight is the most effective way for aviation manufacturing industries to save expense. For example,  Stratasys Fused Deposition Modeling (SFDM) 3D printers generate pieces from the ground up, layer by layer, contrasting conventional production procedures like CNC, which subtract material to make a piece. This process allows for high precision and simplified design features with fewer total elements. This procedure also decreases wastage throughout production because you are infusing materials instead of subtracting them while also bringing incredible weight saving.

Industrial Aviation

Industrial aviation companies such as NASA and SPACE-X are becoming more and more inclined to 3D printing these days. NASA is developing and testing a space crawler that is about the size of a Hummer and has a pressure chamber that can facilitate life on Mars. It has around 70 FDM artificially printed parts right now. Flame-retardant ducts & enclosures, camera attachments, capsule hatches, a huge portion that serves as a front fender, and several other specialized fittings are among the 3D printed pieces aboard NASA’s lander. It’s no surprise that NASA chose 3D printing because the cost of sending a pound of substance to space is estimated to be $10,000.

Another space aviation giant Space-X is taking 3D printing a step further. SpaceX claims to have spent roughly three years perfecting 3D printing expertise for flying gear. They 3D printed a SuperDraco engine cylinder constructed of Inconel, a high-performance, superior alloy (DMLS), utilizing precise metal laser processing. This component was engineered and manufactured in-house.

Its engine chamber effectively ignited at full throttle, generating 16,000 pounds for each engine. SpaceX is currently putting these engines to trial in its manned launch endeavor. When contrasted to conventional machining, 3D printing saves valuable time. It took barely over three months, from the initial sketch to the first hot-fire trial.

Commercial Aviation

Airbus, a top leader in the aviation industry, has a staggering amount of 1,000+ 3D printed components on their latest A350 XWB airplane. Using high-performance FDM elements like ULTEM 9085, they were able to build these parts rapidly and proficiently with the support of Stratasys. This fabrication polymer is indeed a robust, FST-compliant substance with an outstanding strength-to-weight ratio that has been validated to Airbus’s standards.

Future of Aerospace & Additive Manufacturing

You can expect commercial airplanes and spacecraft to employ additive manufacturing technologies with bespoke materials and elevated ultralight thermoplastics to produce essential parts. 3D printing is sure to become a more feasible choice for the aerospace industry as its possibilities grow.

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