Additive manufacturing not only gives wings

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The second block highlights AM for aviation

Using an additively manufactured hydraulic component as an example, Svenja Pestotnik from Liebherr-Aerospace traces the path from the idea through AM-compliant development, the selection of the additive manufacturing method, to aviation certification, as stated. She also addresses the challenges and future potentials. Angelika Jedynak from Chesco demonstrates how her team, in collaboration with Rolls-Royce Germany, succeeded in a parameter study to manufacture combustion chamber segments from the alloy Haynes 282 successfully without support structures. This could optimize the production chain around laser melting without affecting the stability of the printing process and the desired material quality. An insight into the advances in 3D printing with plastics for aerospace—especially under sustainability aspects—is provided by Erik de Zeeuw of Materialise. Finally, Howmet Tital presents an alternative, metallic process to the established additive manufacturing processes in the aerospace sector. The company produces ready-to-install aluminum or titanium components using investment casting and additively manufactures the necessary molds.

Make existing aircraft types more future-proof at a lower cost

How sustainability and cost-effectiveness can go hand in hand is demonstrated by Carsten Holze from Pioneer Aeronautics Innovation (PAI). Together with partners, PAI has aerodynamically optimized the wingtip of an existing aircraft and achieved weight reductions of over 25 percent on a prototype. The manufacturing costs were also halved, as is emphasized. Fuel savings of over ten percent were also achieved. This was made possible through the combination of artificial intelligence (AI)-based analysis and optimization tools with AM manufacturing techniques. "The example illustrates a new trend in the development area. "With AI, digitalization technologies such as digital twins, or the creation of digital product passports, we can unlock further potential for innovative, cost-effective, and reliable AM products for aerospace," Eelman concludes.

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Date: 08.12.2025

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