3D printing – helping shape the future of aerospace engineering

Additive Manufacturing (AM), or 3D printing, will prove a game changer for UK manufacturing. The ability to mass-produce strong and lightweight components with speed and accuracy is closely aligned to the demands of aerospace engineering. It is little wonder that the sector is eager to exploit AM technology. At AE Aerospace we put innovation at the heart of our operation and keep our finger on the pulse of new advancements. It’s exciting to see the opportunities on offer through printed components and what that might mean for the entire aerospace supply chain. 

3D printing can build components layer by layer using a range of materials from metals to polymers. Recent advancements have allowed it to produce complex parts that are both lightweight and robust. This ability to combine light weighting with reliable performance ticks crucial boxes for aerospace OEMs. Producing exact copies in a fast and cost-effective manner, whilst reducing material waste, could revolutionise manufacturing processes.

The technique is on an impressive growth trajectory. According to a recent report by Research and Markets, 3D printing within aerospace and defence is forecast to have a 20% increase in CAGR between now and 2024.

NASA has been working with AM for the last 30 years or so, yet we are now seeing a real acceleration of uptake as technical advancements allow for affordable and practical applications across the wider aerospace market. AM technology is now available to manufacture a whole range of components from engine parts to turbines.

As with any new technology, AM presents challenges and barriers to entry. Can it really satisfy industry regulators and meet our stringent quality and safety standards? Is it also able to scale up and produce larger components?

It seems that new ground is being broken all the time. 3D printing company Materials Solutions recently secured accreditation from the National Aerospace and Defense Contractors Accreditation Program (NADCAP), giving it the green light to begin the production of AM parts. The proverbial floodgates could now open.

For aerospace manufacturers it can seem daunting and risky to invest in emerging technology like 3D printing. Yet help is at hand. A consortium led by the Manufacturing Technology Centre (MTC) is running a three-year research project entitled DRAMA (Digital Reconfigurable Additive Manufacturing facilities for Aerospace). It will help build a stronger AM supply chain for UK aerospace by developing a digital learning factory.

The project was born out of a need to help OEMs and component manufacturers to take the lead in exploiting AM. Many are put off taking the leap due to the risks associated with setting up AM processes, buying equipment and developing the necessary supply chains.

The ￡14m project will develop a digital learning factory, de-risking the AM process by trialling hardware and software within a tailored virtual environment. It uses a series of digital tools to allow users to test different scenarios and find the best solution for their business.

Beyond the virtual factory, businesses can access an AM Knowledge Base and model and validate AM process chains in reconfigurable pre-production facilities. This support mechanism could prove invaluable for manufacturers who are reticent about experimenting with new ways of working.

Our recent growth is a result of an ongoing commitment to invest in people, plant and processes. It’s a fast-moving market and you have to keep innovating to stay ahead of the game. It is encouraging to see that there is support in place to help manufacturers right across our sector learn more about emerging technologies and then apply that knowledge to their own operation. We’ll be keeping a close eye on the application of 3D printing and the opportunities it unlocks for businesses across the supply chain.