Printed up high Additive manufacturing not only gives wings

Corona is over, air traffic and aerospace have a tailwind. At the Rapid.tec 3D in Erfurt, experts demonstrate what additive manufacturing can achieve in this context ...

How additive manufacturing (Additive Manufacturing = AM) can make an optimizing contribution in aerospace will be the subject of the Rapid.tech-3D Aerospace Forum on May 13, 2025, as informed by Messe Erfurt, the organizer of Rapid.tech 3D. The 2025 forum will focus on AM applications that are both innovative and profitable. "In aerospace, it's essentially always about getting airborne with as little weight as possible and high functional integration in the smallest space," explains Stephan Eelman, who, as Head of Strategy for Europe at Boeing, has been responsible for the forum's content since 2022. Additive manufacturing can create innovations that would otherwise be difficult to realize, as it further says.

Most of the time, the first attempt has to hit the mark

But despite all the design freedom, 3D printing must also be profitable—especially in the context of qualification and certification. "This means that with often very low quantities—such as in aerospace—the first attempt must be spot on," as Eelmann emphasizes. Therefore, the focus of the Aerospace Forum is clearly on applications that offer added value and have already proven this in practice. How additive manufacturing drives future aerospace applications is already the subject of the opening keynote, right before the forum. Dr. Karl-Heinz Dusel from MTU Aero Engines also considers innovation and profitability aspects. He points out that especially the cost reduction for 3D-printed components is a key to their broader use in the aerospace industry. He also presents approaches for implementation, as it further states.

This is how 3D printing expands the boundaries of space travel

The first block of the forum focuses on 3D printing applications for space travel. Dr. Aaron Pfaff from the Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach-Institut EMI presents a successful application of multidisciplinary topology optimization and generative design in the field of nanosatellite technology. This is demonstrated using the example of Ernst. This is the first small satellite to support military tasks in Germany. Its infrared camera detects, for example, missile launches. The insights gained from the Ernst mission are incorporated into future developments of nanosatellites.

Ariane 6 has also successfully launched into space with AM components. On its maiden flight, it had several additively manufactured and qualified components on board, which have a technology readiness level of 9 and thus the status "flight-qualified." Dr. Steffen Beyer from the Ariane Group will report on how the project became economically successful. He demonstrates this with the so-called Auxiliary Power Unit (APU), which was created using laser beam melting. Due to the complex design of this auxiliary unit, which significantly contributes to the versatility of the Ariane 6 upper stage, additive manufacturing was able to unleash its full potential.