How Are Lithoz Ceramic Materials Revolutionizing Aerospace?

It is predicted that the ceramic 3D printing market will generate up to $4.8 billion worldwide in 2030. And one large and important customer for ceramic 3D printing is the aerospace industry. A notable player in the sector is Vienna-based Lithoz, which has focused on ceramic 3D printing for the aerospace sector, among others. Lithoz has succeeded in developing a manufacturing system based on lithography-based ceramic manufacturing (LCM). This makes it possible to increasingly use ceramics for aerospace applications. But what specific possibilities and areas of application does ceramic 3D printing and the materials developed for it have in this case? And how do they contribute to improving the requirements of aerospace to date?

Spaceships Take Off With 3D Printed Ceramic Parts

Faster, simpler and more cost-effective is the principle that many companies and organizations in the aerospace sector are pursuing. There is hardly any other sector like aerospace where the requirements and expectations for additively manufactured parts are as high. Probably the greatest challenges for its components include not only extreme loads but also heating and overheating. In particular, the fact that turbine blades move at such a speed that the heat generated by them is higher than that generated by the metal used to make them pushes conventional manufacturing processes to their limits. However, the individual components must not only be able to withstand excessive heat without problems, but also freezing cold. If one considers that the outside temperature in space can quickly drop to over – 200 °C, it quickly becomes clear: the Aersospace sector needs a forward-looking alternative for the manufacturing process. These different extreme conditions must not affect the performance of the parts in any way, as continuous stability and porosity are essential in space travel. The size for catalysts, for example, also plays a major role downstream: if the parts are manufactured too large, it can lead to unnecessary heat loss; if the parts are too small, it can lead to no maximum decomposition of the propellant. The result in both cases is reduced performance and increased cost.

But how can ceramic 3D printing remove these obstacles? Ceramics are known for their properties such as heat resistance, mechanical performance, and also for their use in producing fine components of the highest quality. Additive manufacturing therefore enables the design of complex shapes while reducing costs and lead times – something that is not possible through conventional manufacturing. It can be quickly deduced that ceramic 3D printing is an ideal solution for an industry as demanding as aerospace. Lithoz has quickly positioned itself in this market by developing a silicon nitride (Si3N4) that shines with its optimal properties, such as tremendous strength even at high temperatures, excellent resistance to unexpected temperature changes, and also tremendous hardness. To prove these properties and test the material under extreme conditions, the Austrian company conducted a stress test with a nozzle made of Si3N4 – with excellent results.