Using Ceramic 3D Printing to Achieve Complex Aerospace Structures

Industries are increasingly searching for new and advanced materials and processes to improve their products, and the aerospace sector is no exception. The industry’s needs are evolving rapidly with the introduction of more stringent requirements. Thus, they demand new technologies that can provide innovative and efficient solutions. Additive manufacturing is emerging as an ideal solution for aerospace applications. According to a report by Research and Markets, the aerospace and defense market’s value for 3D printing was estimated to be $1.9 billion in 2021, with an expected CAGR of over 24% from 2022 to 2027. Additive technologies are bringing significant changes and advantages to the aerospace industry, such as the production of lighter, stronger, and more complex parts, design freedom, the ability to combine multiple parts into a single unit, the reduction of waste of costly raw materials, and cost and resource efficiency.

If we look at the innovative materials that can be used through 3D printing, the one that is gaining most success is ceramics. This has proven to have the necessary properties to meet the needs of industry and the high standards required in aerospace applications. Among the companies that have focused on ceramic additive manufacturing is Austrian manufacturer Lithoz, which has developed Lithography-based Ceramic Manufacturing (LCM) technology for complex parts with high resolutions. The company doubled the sales of its ceramic 3D printing solutions and turnover in the year 2022, indicating market interest in this technology in multiple industries, including medical and aerospace.

A 3D printed ceramic part

The Benefits of Using Ceramics in Aerospace Applications

The research report titled “3D Printing Ceramics 2022-2032: Technology and Market Outlook” highlights the significant growth in the value of the ceramic 3D printing market, estimated to reach $400 million by 2023. According to the report, the aerospace, defense, dental, and chemical engineering industries are the most interested in ceramic manufacturing for producing small-batch parts. Ceramics have captured the attention of the aerospace industry due to their exceptional properties, such as high resistance to heat, oxidation, and abrasion as well as mechanical and dimensional stability. This makes ceramics highly efficient and suitable for use in extreme conditions, making it an ideal material for next-generation spacecraft construction, especially for parts exposed to high stresses. We mainly refer to “advanced ceramic materials” or “technical ceramics” which possess remarkable properties such as high strength, corrosion resistance, and excellent thermal and electrical insulation. Some of the most noteworthy advanced ceramics are aluminum oxide (Al2O3), silicon nitride (Si3N4), silicon carbide (SiC), and zirconia (ZrO2). Via 3D printing, even ultra-high temperature ceramics (UHTCs) can be processed, the material properties of which are extremely sought-after in this industry.