Aerospace 3D Printing Innovations

🚀 Our latest paper has been published in Progress in Additive Manufacturing - “Performance and microstructure analysis of cylindrical rods fabricated by dot-by-dot WAAM for aerospace applications” 📄 https://lnkd.in/d_mKjGBy In this work, we explored the use of dot-by-dot Wire-Arc Additive Manufacturing (WAAM) to fabricate lightweight, load-bearing cylindrical rods for topologically optimized aerospace components. We focused on optimizing welding parameters, analyzing microstructures, and validating performance through destructive and non-destructive testing. Some key findings: ✅ Dot-by-dot WAAM enables significant weight savings while maintaining mechanical integrity ✅ PMC welding mode resulted in lower porosity and better mechanical performance than CMT ✅ Achieved UTS up to 187 MPa and 4.9% elongation in rods using optimized PMC settings This was a true team effort: 🤖 Yiğit HERGÜL tackled the robotic path planning 🔬 Tansu Göynük led the metallurgical analysis 🔥 Murat Yucel and Gokhan Can were the welding maestros behind the builds A huge thanks to all of them for their dedication and expertise! 📽️ Check out the video below to see our dot-by-dot WAAM process in action — featuring a load-bearing spiral structure. #AdditiveManufacturing #WAAM #WireArcAdditiveManufacturing #AerospaceEngineering #Robotics #MaterialsScience #MetalAM #Research #TopologicalOptimization #Microstructure #3DPrinting #PMC #CMT #NDT #WeldingInnovation

In December 2022, GE announced a turbine centre frame made with laser 3D printing. Just one year later, Zhang’s team presented a component larger and more complex than GE’s, the intermediate casing. Over a metre in diameter, it features bionic grooves just 15 to 35 micrometers deep – thinner than a human hair. It was previously considered impossible to manufacture such a large hard alloy component using a 3D printer while maintaining precision at such a fine scale. The intermediate casing is the most important and complex load-bearing structural component of an aviation engine. It not only connects the engine’s front intake fan and the compressor but also serves as the connection between the engine and the aircraft fuselage. The intermediate casing needs to withstand the impact of high-pressure and high-temperature gases while transmitting the engine’s thrust and torque to the aircraft. Despite being just 3mm (0.11 inch) at its thinnest point, it can bear over 10 tonnes of load, posing significant design and manufacturing challenges. Using mainstream 3D printing technology and commercial software, Zhang’s team created a prototype that is 25 per cent lighter than traditional castings, yet strong enough to withstand impacts like bird strikes.

✈️ Did you know a drone can fly without conventional control surfaces? 👀 In 2020, CMASLab at ETH Zurich developed and successfully flight-tested a fixed-wing drone that controls roll, pitch, and yaw purely through shape change. 👉 No flaps 👉 No hinges 👉 No traditional moving control surfaces What makes this truly disruptive isn’t just the aerodynamics — it’s how it was built: 🧵 The entire structure was additively manufactured using continuous carbon-fiber composites 🖨️ Fabricated with the 3D-printing system developed by ETH spin-off 9T Labs 🧠 Fiber orientation was fully tailored to exploit material anisotropy and real load paths Why does this matter? Morphing structures depend on: • compliant mechanisms • complex internal geometries • deep structural integration All of which are extremely difficult — and expensive — to produce with traditional manufacturing. This project demonstrated a different path forward: ✨ Lower manufacturing costs ✨ Higher structural efficiency ✨ Improved aerodynamic performance 📌 For the first time, both the primary structure and the morphing mechanisms of a fixed-wing drone were 3D-printed in composites — and actually flown. When materials, manufacturing, and aerodynamics evolve together, we don’t just optimize designs — 👉 we redefine what aircraft structures can be. #AviationInnovation #AdvancedManufacturing #Composites #MorphingStructures #AerospaceEngineering #FutureOfFlight

Designing rocket engine components is the easy part—manufacturing them to meet all intended design requirements with repeatability and reliability is tough! Additive manufacturing (AM) enables complex geometries, eliminates the specialty skills for brazing or plating, and speeds up prototyping or production, but still has a lot of challenges. One major challenge in AM is surface texture—roughness, waviness, and form—all impacting performance in different ways. This paper represents years of research on laser powder directed energy deposition (LP-DED) for large-scale heat exchangers, such as rocket nozzles with microchannels. We explored surface finishing techniques for internal channels and their effect on friction factors, aiming to tune flow conditions to meet the design requirements. https://lnkd.in/eDxesQFx #additivemanufacturing #3DPrinting #3DPrint #aerospace #rockets #manufacturing #rocket #nasa Piero Angelo NASA - National Aeronautics and Space Administration NASA Marshall Space Flight Center

In aerospace and defense manufacturing, one of the trickiest challenges has long been creating hollow composite structures with internal geometries that would typically require labor-intensive, multi-step tooling and sacrificial core removal. However, using 3D-printed wash-away cores is changing all of that. Its cores are printed with binder jet technology, coated for composite lay-up, and then washed out, eliminating severe distortion and the pain of manual extraction. The approach lets engineers create complex mandrels with controlled thermal expansion and isotropic behavior during autoclave curing, but also allows reuse of the wash-out material, adding a sustainability advantage.

The pace of innovation is accelerating....rapidly Just came across this fascinating research from Caltech that's "bringing metallurgy into the 21st century" - and and it illustrates why materials science is so exciting right now. Researchers have developed a method to 3D print metal alloys with unprecedented precision, controlling both composition AND microstructure at the microscale. The result? Copper-nickel alloys that are up to 4x stronger than traditional versions. What makes this remarkable: → Complete control over metal composition ratios → Custom-designed properties for specific applications → Potential for everything from biocompatible medical stents to ultra-durable satellite components The new approach offers significantly more control over material properties than traditional methods. Being able to precisely specify composition and predict characteristics could enable new applications across medical devices, aerospace, and other fields where material performance is critical. The technique (called HIAM - Hydrogel Infusion Additive Manufacturing) starts with 3D printing a polymer scaffold, infuses it with metal ions, then uses controlled heating to burn away the organic material and leave behind precisely engineered alloys. This is what makes this moment special for deep tech: We're witnessing the convergence of AI and materials science. Machine learning is accelerating materials discovery, while breakthroughs like this are enabling precise control over atomic-level engineering. The combination is creating possibilities we couldn't even imagine a decade ago. The world is changing rapidly, and deep tech innovations are at the center of it all. This isn't just another research paper - it's a glimpse into how we'll solve tomorrow's biggest challenges. This is why deep tech deserves serious attention right now. What industries do you think will be transformed first by this kind of precision materials engineering? https://lnkd.in/gaUeEV2g #Innovation #MaterialsScience #3DPrinting #Engineering #Research #Technology #DeepTech

🔥 Increasing the Durability of 3D-Printed Metals 🌟 Overview Imagine printing a metal part where materials transition seamlessly between regions, combining the toughness of steel with the heat resistance of a superalloy. This is the promise of Functionally Graded Materials (FGMs) produced using Directed Energy Deposition (DED). Here’s the catch: residual stress—baked into the structure as it cools—threatens to compromise its strength and usability. A recent breakthrough from researchers at UBC introduces a powerful analytical model to predict and mitigate residual stress, unlocking the full potential of FGMs for high-performance applications like aerospace and biomedical devices. 🤓 Geek Mode Residual stress forms when dissimilar materials (like steel and Inconel) expand and contract unevenly during cooling. This model factors in real-world complexities—material gradients, heat transfer, and plastic deformation—to deliver precise predictions. Key insights: 1️⃣ Vertical transitions (e.g., layer-by-layer gradients) increase tensile stress near boundaries, raising the risk of cracks. 2️⃣ Horizontal transitions can distribute stress more evenly but tend to compress surface layers. 3️⃣ Strategic material gradients can minimize weak points while retaining desired properties. The team validated their model with X-ray diffraction tests, achieving predictive accuracy within 20%, outperforming previous simulations. 💼 Why It Matters for Industry From turbine blades to dental implants, FGMs are transforming how we think about durable, custom-engineered components. By solving the stress puzzle, this model enables manufacturers to design parts that meet rigorous safety and performance standards, paving the way for reliable, large-scale production. 🌍 Impact Beyond Manufacturing Reduced waste, fewer defects, and better resource efficiency: innovations like this don’t just improve products—they help reduce the environmental impact of advanced manufacturing. Imagine aircraft engines that last longer or medical implants that integrate seamlessly into the human body. This research highlights the role of deep technical insights in turning futuristic concepts into everyday solutions. As DED technology advances, the ability to engineer stress-free, high-performance materials could become the new normal. 📄 Original paper: https://lnkd.in/gPd9arh2 #AdditiveManufacturing #DeepTech #MaterialsScience #EngineeringInnovation

Printed in thin air… Researchers at Jiangnan University in China found a way to 3D print ceramic parts without supports. They combined direct ink writing with a near-infrared laser that cures the slurry as it leaves the nozzle. Rigid ceramic lines drawn in space. No scaffolding needed. Filaments from 0.4 to 3.5 mm stayed rigid, fast enough to build springs and cantilevers directly. Compared to UV curing, it’s more than 100 times quicker and much deeper. Aerospace, energy and electronics all rely on ceramics that resist heat and corrosion. Cutting out supports makes those parts easier to design and clean up. Of course there are limits. Making bigger parts won’t be easy, and the process relies on exotic particles with cost and environmental downsides. Still, taking supports out of the picture is a big deal. Could this finally move ceramics closer to factory use? Daily #electronics insights from Asia—follow me, Keesjan, and never miss a post by ringing my 🔔 #technology #innovation