Recent 3D Printing Applications in the Aeronautics Sector

Additive manufacturing is amazing for producing lightweight, strong and geometrically complex parts—so the technology is particularly valuable in the aeronautics sector, where strength and weight optimization are critical. Aeronautics is the science and practice of designing, building, and flying all aircraft, except those that go into space. The sector was one of the earliest adopters of AM, initially using it for rapid prototyping. Today, however, its applications have expanded to include end-use parts in airplanes, helicopters, drones and more. To showcase the versatility and impact of 3D printing in this field, we have compiled a list of some of the most recent and remarkable applications of AM in aeronautics.

Norsk Titanium Supplies Parts for Boeing 787, Launches Supplier Partnership

Norsk Titanium US Inc., a leader in titanium additive manufacturing and active in the aerospace industry, already supplied parts for the Boeing 787 Dreamliner in 2021. The company is best known for its patented Rapid Plasma Deposition® technology, which improves the strength and durability of the finished part and works similarly to directed energy deposition (DED). Norsk’s technology is different because it uses an electron beam to heat powder in several places simultaneously. Among the parts they created were 3D printed titanium components certified by the FAA (Federal Aviation Administration). Now the company has agreed to supply volume production parts directly to The Boeing Company, marking the beginning of a direct supplier relationship. Norsk Titanium expects to provide hundreds of structural parts by 2025. ““Our RPD® technology and established material specifications position Norsk Titanium to react quickly to the demands of our customers,” explains Nick Mayer, VP of Commercial.

ITP Aero Obtains EASA Certification for 3D Components

Based in Vizcaya, ITP Aero has successfully obtained certifications from the European Aviation Safety Agency (EASA) and the Spanish Aviation Safety Agency (AESA) for 3D-printed structural components. The company thus becomes the first in the aero engine industry to receive these approvals for parts manufactured using selective laser sintering (SLS), applied to the rear blades of the TP400 engine. This industrial additive manufacturing process allows the creation of complex components using less material and energy, which contributes to the sector’s sustainability. In addition, ITP Aero has developed its own additive manufacturing standards and specifications for high-temperature aero-engine components. The company has a dedicated manufacturing cell and is building the “ADMIRE” research center to further advance digital and sustainable manufacturing technologies.