Aerospace 3D Metal Sintering

Using innovative, tool-less laser sintering, 3D Metal Printing enables cost-effective production of lightweight high-tech components, even with small batch sizes. Engine and turbine parts as well as cabin interior components are typical applications. 

This is where the benefits of using 3D Metal Printing come to the fore:

functional components with complex geometries and defined aerodynamic properties can be manufactured quickly and cost-effectively. Material and weight savings lower fuel consumption and CO2 emissions.

Lightweight Design:

Intelligent lightweight structures manufactured by 3D Metal Printing combine high strength with a weight reduction of 40–60%. The material savings translate into more flexibility in design and engineering. As a result, airplanes consume significantly less fuel and emit less carbon dioxide.

Tool-less:

3D Metal Printing enables maximum flexibility in production planning. Modified parts, upgrades and spare parts can be produced as needed, obviating the need for storage. Given the long service lives of airplanes, additive manufacturing processes yield clear cost benefits.

Interior:

3D Metal Printing enables aerospace companies to produce tailor-made, high-quality parts for cabin and cockpit equipment. 3D Metal Printing creates new possibilities for aerospace companies producing cabin and cockpit equipment. Functional components such as lightweight belt buckles made of high-quality Ti64 titanium can be manufactured quickly and cost-effectively using metal laser sintering technology. 3D Metal Printing gives maximum flexibility in product design and manufacturing. 3D Metal Printing enables just-in-time series production of modified parts, upgrades and spare parts, even in small production runs. This enables fast and profitable fulfilment of airline-specific individualisation requirements, such as VIP solutions, retrofits or designer interiors. Even one-off pieces do not cause added cost. This obviates the need and expense for the storage of numerous spare part versions. Using innovative 3D Metal Printing laser sintering equipment, aerospace companies can implement successful and sustainable strategies for the design and manufacture.


Cost Reduction:

Since 3D Metal Printing doesn’t need set-up and tooling costs, production costs are only incurred for the parts themselves, at the time they are manufactured. Even small production runs and one-off pieces do not cause added cost. In addition, system parts designed for optimum function can often be realised as a single part, simplifying assembly and quality assurance.

Engines:

The benefits of Additive Manufacturing (AM) come to the fore in the production of engine and turbine parts, even for small batch sizes. Functional parts with demanding geometries and defined aerodynamic or fluid-dynamics properties can be manufactured quickly and cost-effectively using 3D Metal Printing. That includes fuel systems, guide vanes and turbine blades, add-on systems and special heat protection components. 3D Metal Printing can deliver even extremely complex components made from high-strength material, which may contain cavities or oil lines, while the use of conventional manufacturing processes for such parts is either impossible or very expensive. In addition, 3D Metal Printing enables the development of advanced lightweight designs, which combine high strength with a weight reduction of up to 60 per cent. The use of such innovative components lowers fuel consumption and CO2 emissions.