Additive manufacturing for the Aerospace industry

Additive manufacturing is not only part of the future, but also of the present in the aerospace sector. The need to make lighter parts, with higher quality mechanical properties while using more efficient materials is a perfect match for additive technologies.

Learn about all the innovations of additive manufacturing for the aerospace industry and ask us for advice now.

PRIMA ADDITIVE FOR AEROSPACE

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The adoption of additive manufactured parts is not only advantageous in terms of aircraft functionality, but also means a real respect for the environment and sustainability within aerospace. Reducing the weight of an aircraft simultaneously reduces the aircraft's fuel consumption and, as a result, its CO2 emissions.

Similarly, in the space sector, reducing the weight of a satellite or its launch vehicle reduces the cost of launch, thus enabling lower barriers to entry, opening up new opportunities for the space economy.

It is not only weight that is crucial when it comes to the aerospace industry, but also mechanical characteristics, material performance and, above all, component reliability. Metal additive manufacturing enables both to produce parts with unrivalled mechanical properties and absolute dimensional accuracy, as well as identifying new materials that are more efficient and reliable.

SET SQUARE

Design Freedom and Complexity

Additive manufacturing (AM) enables the creation of complex geometries and intricate designs that are difficult or impossible to achieve with traditional manufacturing methods. This allows for the production of lightweight, structurally optimized aerospace components with enhanced performance characteristics, contributing to significant improvements in fuel efficiency and overall aircraft performance.

Cost Efficiency and Material Savings

AM processes, such as Directed Energy Deposition (DED) and Powder Bed Fusion (PBF), build components layer by layer, which significantly reduces material waste compared to subtractive manufacturing methods. This not only lowers the cost of raw materials but also contributes to more sustainable manufacturing practices. Additionally, the ability to produce components directly from digital models can reduce lead times and inventory costs.

RECYCLING

Improved Sustainability and Environmental Impact

The aerospace sector benefits from AM's ability to produce lighter components that directly contribute to improved fuel efficiency and reduced CO2 emissions during flight. By optimizing part designs for weight reduction without compromising strength or safety, AM plays a crucial role in the aerospace industry's efforts to minimize its environmental footprint.

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Especially in the aerospace sector, it is essential to comply with stringent industry standards, above all NADCAP certification (National Aerospace and Defense Contractors Accreditation Program).

Prima Additive can support you through the entire certification process, including process verification, powder verification and finished product testing, to enable you to obtain certification and produce additive parts using a standardized, repeatable and qualified process.

We are at your service to help you take full advantage of the shape flexibility made possible through metal additive manufacturing.

Main Applications of Metal Additive Manufacturing in the Aerospace Sector

Behind every innovation there is a Prima Additive machine

  • Engine Components: The production of complex engine parts, such as fuel nozzles, turbine blades, and heat exchangers, benefits from AM's capability to create lightweight, high-strength structures with improved thermal properties.
  • Structural Components: AM is used to manufacture critical structural aircraft components, including brackets, frames, and fuselage parts, which are designed for strength and weight optimization
  • Prototyping: Rapid prototyping of aerospace components allows for faster iteration and testing, significantly reducing the development time for new aircraft designs and modifications.
  • Customized Parts and Tooling: AM enables the production of customized parts and tooling for specific applications, including jigs, fixtures, and molds, with reduced lead times and costs.
  • Repair and Maintenance: Directed Energy Deposition (DED) and other AM processes are employed for the repair of high-value components, extending their service life and reducing maintenance costs.
  • Spacecraft Components: The manufacturing of parts for spacecraft and satellites benefits from AM's ability to produce lightweight components that withstand the extreme conditions of space missions.
  • Interior Cabin Parts: Additive manufacturing is used to create customized interior cabin components, such as seat frames and ventilation system parts, optimizing for comfort and efficiency.

By leveraging the unique advantages of metal additive manufacturing, the aerospace sector is able to achieve unprecedented levels of performance, efficiency, and innovation in the design and production of aircraft and spacecraft components.

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