Additive manufacturing for aeronautical component production
A revolution to the aerospace industry
Additive manufacturing is revolutionising the production of aeronautical parts thanks to advanced 3D printing technologies. This process makes it possible to create complex metal parts by depositing layer by layer a specific powder, fused by a laser. Using different techniques, manufacturers can reduce the weight of parts, improve their performance and limit material waste. The boom in specialised printers and the evolution of materials are reinforcing the adoption of these technologies in the aeronautic sector. This innovative process is redefining the production chain, offering solutions tailored to the sector's requirements while pushing back the boundaries of traditional manufacturing. Find out more about the challenges and benefits of additive manufacturing for the production of aeronautical components in this article. For other processes, discover Siemens solutions for the aerospace and defence industry.
The challenges of using additive manufacturing in the aerospace industry
The aerospace industry, always at the forefront of technological innovation, uses specialised additive manufacturing process such as SLM (Selective Laser Melting) for metal parts. Among the processes used, powder bed fusion (PBF) stands out for its precision and its ability to optimise component design. This process creates complex metal parts by depositing layer by layer a specific powder, fused by a laser.
One of the main challenges of this manufacturing process is to meet safety standards. Aeronautical components must be able to withstand extreme environments while maintaining high strength and impeccable quality. This type of printing process optimises the design and strength of parts by printing them using laser fusion on a metal powder bed.
Environmental aspects also play a key role. The reduction in the amount of material consumed, thanks to the precise deposition of layers, makes it possible to minimise the waste of powders and metal wires. This approach is in line with the industry's new ecological requirements.
Another major challenge is improving working conditions. The technical handling of heavy and dangerous materials is simplified by the use of a printer that works with metal powders or wires, deposited layer by layer via a laser or other process without direct contact.
Finally, the industry requires optimal weight reduction for each part. A lighter aircraft consumes less energy, which improves its efficiency and reduces its carbon footprint. Complex 3D models optimise load distribution and increase component reliability. In addition, additive manufacturing reduces production costs by limiting the use of moulds and speeding up the manufacturing process.
As a result, additive manufacturing helps your company to meet a wide range of industrial challenges. The aerospace industry requires cost-effective production and precision, with the manufacture of strong, light, complex parts in large, heavy materials. Find out more in the next section about the benefits of additive manufacturing.
Additive manufacturing methods
Additive manufacturing methods include various techniques such as 3D printing, composite manufacturing, powder bed fusion (PBF), material and binder injection, vat photopolymerisation, direct energy deposition and material extrusion. These technologies speed up production by enabling rapid prototyping.
Advantages of additive manufacturing in the aerospace industry
The most commonly used processes in the aerospace industry are SLM (selective laser melting) and FDM (fused deposition modelling), which use a laser beam to deposit powder or metal wire. These techniques offer a number of major advantages:
-
Weight reduction: material deposition printing (powder and wire) is a selective technology that optimises the weight of your objects. This process enables deposition to be precisely regulated to eliminate any superfluous material from your final products. This improves energy efficiency and reduces operating costs.
-
Complex geometry parts: 3D printing is a technology that optimises precision manufacturing. Processes such as topology optimisation push the use of materials such as metal powder to create solid internal structures and elaborate structures. This process gives the materials a certain resistance.
-
Customised manufacturing: additive manufacturing enables rapid, customised printing of metal parts, meeting the recurring need for replacements in the aerospace industry. The use of a printer reduces the need to stock finished products and allows parts to be produced only when needed, minimising material waste and optimising costs while respecting the environment.
- Elimination of moulds: a process such as SLM completely eliminates the need for moulds, which are time-consuming and costly to manufacture, as the printer creates the object directly from the chosen material. This technique provides greater flexibility for a variety of applications, and the optimisation of the quantity of material used results in a reduction in waste. Production is also more efficient, since the layers of material are deposited with great precision, without excess.
- Optimised parts: advanced material deposition technology enables the design of metal objects to be adapted to merge several sub-assemblies into a single object. Reducing the size of assemblies results in lighter objects with improved strength, performance and durability.
- Solidified parts: instead of assembling several elements, a single part can be produced by adding metal layers, thereby improving internal strength and reducing the number of interfaces sensitive to mechanical stress.
As you can see, additive manufacturing represents a major technological, economic and environmental advance. Thanks to processes such as SLM and laser printing, it optimises the design of objects, reducing costs and lead times while limiting material consumption and waste. This technology has a wide range of applications in industry, contributing to more sustainable production. In the future, improved materials and the integration of multi-materials will further extend its possibilities, enhancing reliability and quality while reducing its environmental impact.