Additive manufacturing in aerospace has rapidly transformed the industry by producing lighter, stronger, and more efficient components that improve performance and reduce lifetime costs. Aerospace 3D printing uses additive manufacturing (AM) to produce components with highly complex geometries while reducing material waste and improving lead times, compared to traditional manufacturing methods. 3D printing for space applications includes producing customized, lightweight parts for satellites, rocket engines, thrusters, and space suits, while on-demand in-orbit manufacturing reduces costly resupply missions and supports long-duration space exploration. 3D printing in aviation has been adopted for 3D printed airplane parts, including jet engine components, structural supports, and interior cabin elements, as well as parts for drones and other unmanned aerial vehicles (UAVs). Aerospace 3D printing encompasses multiple process types, with standards organizations and trade organizations defining distinct processes. The Association for Manufacturing Technology (AMT) recognizes 17 distinct processes, including a hybrid AM-traditional machining method in order to fully represent the AM industry. ASTM International (formerly known as the American Society for Testing and Materials), an international standards organization, recognizes seven processes to provide clear guidelines based on the fundamental physics of each process. The most common processes in aerospace 3D printing are: Laser powder bed fusion (LPBF) Directed energy deposition (DED) Electron beam powder bed fusion (EBPBF) Material extrusion (ME) Binder jetting (BJ) Each offers unique advantages in material compatibility, build speed, resolution, and post-processing requirements that make them suitable for specific aerospace components. Material selection is critical in aerospace additive manufacturing. Titanium and aluminum alloys are widely used for structural parts, brackets, and airframe components, while nickel-superalloys and copper alloys support high-temperature engine and propulsion system applications. Polymers, composites, and ceramics are also increasingly used for lightweight interior parts, thermal protection systems, and specialized components, reflecting how 3D printing in aerospace is expanding material options to meet the industry’s high-stress, high-performance requirements. AM is also reshaping supply chains by enabling on-demand production and reducing reliance on complex global supply chains. As industry certifications and standards for AM mature and expand, manufacturers and original equipment manufacturers (OEMs) are increasingly adopting AM for mission-critical parts in both aviation and space. What Is Aerospace 3D Printing? Aerospace 3D printing refers to the use of additive manufacturing (AM) to produce components in aircrafts, drones, spacecrafts, and other related systems. AM creates these parts via a layer-by-layer approach from computer-aided drafting/computer-aided modeling (CAD/CAM) design files. Compared to traditional subtractive manufacturing methods, AM enables the production of customized parts with complex geometries using lighter materials in order to reduce overall material waste and shorten manufacturing lead times. Applications for Additive Manufacturing in Aerospace Additive manufacturing has been used in many critical applications within the aerospace industry, including rapid prototyping, tooling, and mass part production. Its integration into various aerospace systems has been driven by the need for lightweight, high-performance parts, reduced material waste, and streamlined supply chains with reduced international dependence. AM has enabled production of complex parts previously inaccessible or cost-prohibitive with traditional manufacturing methods. The use of AM is redefining how aerospace systems, including drones, unmanned aerial vehicles, jet turbines, and rocket engines, are designed, produced, and maintained or repaired.1–4 General Uses for 3D Printing in Aerospace General uses for additive manufacturing in aerospace applications includes rapid prototyping and tooling, capacity to mass produce large-scale parts with complex geometries, production of upgraded or replacement parts for maintenance and repairs, and mass customization for low-volume, high-value parts. These capabilities reduce production lead times and minimize supply chain dependencies. The aerospace industry has been gradually adopting additive manufacturing processes to produce various components over the past two decades.5 Two main factors for AM’s integration in the aerospace industry are decreased material waste and reduced fuel consumption; both benefits result from the manufacturing technology’s ability to create lighter, optimized parts.6 Additionally, increasing guidance and standards creation for material, part, and process qualification from authorities including the Federal Aviation Administration (FAA), the International Organization for Standardization (ISO), ASTM International, and the National Aeronautics and Space Administration (NASA) aid widespread 3D printed aerospace part adoption.7–10 3D Printing for Space AM has been used for space applications, including parts for satellites, rocket engines, thrusters, heat exchangers, and space suits due to its ability to rapidly prototype and develop lightweight parts with optimized material properties.2,11,12 There have also been recent efforts to install 3D printers in space to provide on-demand, in-orbit repairs and maintenance, reducing the need for time-consuming and costly resupply missions from Earth.12,13 A main advantage of 3D printing for space applications is the ability to produce components with optimized strength-to-weight ratios – critical for both launch efficiency and in-orbit performance.7 For example, NASA developed an aluminum-based rocket nozzle with internal cooling channels using a directed energy deposition AM process, resulting in a lighter-weight alternative to conventional nozzles.14 The aluminum powder was developed via industry partnerships, which NASA leverages to advance its supply base and increase AM’s accessibility for the aerospace industry.14 Many companies are focused on leveraging AM for space applications. For example, EOS (IMTS booth 338450) offers direct metal laser sintering 3D printers used to produce parts for launch vehicles and satellite systems, and Stratasys (IMTS booth 338460) has developed qualified materials for its Stratasys F900 platform for high-temperature, chemical-resistant parts for use in mission-critical aerospace applications. You can find out more about how these and other companies are using 3D printing for space applications at our IMTS 2026 show. 15 The use of 3D printed aerospace parts in space applications reduces payload weight and opens the door for on-demand manufacturing and repairs in orbit, streamlining logistics and maintenance strategies for long-term missions. 3D Printing in Aviation AM is increasingly being used in aviation to produce components with complex geometries, reduced part counts, and improved structural integrity for commercial jets, military aircrafts, drones, and UAVs. There are many benefits to using AM for aviation applications. Lighter materials reduce overall payload, which lowers fuel consumption and resulting emissions. The ability to consolidate parts reduces potential failure points and the overall assembly time. Localized production of AM parts minimizes inventory costs and reliance on fragile supply chains.1,16 Examples of 3D printing in aviation include: Jet engine components, such as heat exchangers, fuel nozzles, and turbine blades Drone and UAV components, such as body frames and housings 3D printed airplane parts, such as airframe brackets and structural supports composed of titanium and aluminum alloys Interior cabin components, such as seat frames and ventilation ducts A well-known success story of AM in aviation is GE Aviation’s use of AM to consolidate a twenty-part fuel nozzle into one 3D printed part, resulting in improved durability, longer service life compared to the traditionally machined component, and a weight reduction of 25%.1 Now known as GE Aerospace, the company has implemented the fuel nozzle in the CFM Leading-Edge Aviation Propulsion (LEAP) engine program, a new engine developed as a joint venture with Safran Aircraft Engines. By combining the 3D printed nozzle with advanced materials and composites, the LEAP engine achieves 15% lower emissions than its predecessor, the CFM56, and is used across all variants of the Airbus A320neo, Boeing 737 MAX, and COMAC C919 aircrafts.17 As the certification processes and regulatory framework become more standardized, the adoption of AM in aviation is expected to grow rapidly, especially in applications for maintenance, repair, and overhaul (MRO) and on-demand spare part production. Pros and Cons of Aerospace 3D Printing 3D printing is well-suited for production of lightweight, high-strength parts and offers a high degree of design freedom with minimal material waste. However, it does not replace the need for traditional manufacturing methods, which are better suited for high-volume, simple parts that require cost-effective production with long-established, certified reliability. Table 1: Benefits of additive manufacturing in aerospace applications1,16 Benefits of AM Lightweight and Strong Parts Parts with optimized geometries reduce weight without compromising strength Critical for improved fuel efficiency and increased payload capacity Design Freedom AM allows for part integration and consolidation Reduces part assembly time and potential failure points Reduced Material Waste AM builds parts layer-by-layer, resulting in less material waste Beneficial when working with expensive materials, such as titanium On-Demand and Localized Production Reduces dependence on international supply chains by producing parts closer to point of use Reduces inventory quantities and associated costs Table 2: Limitations of additive manufacturing in aerospace applications1,16 Limitations of AM High Initial Cost Industrial 3D printers and materials can be expensive, with AM systems ranging from $5,000 to over $1 million USD Limited Material Options While the materials available for 3D printing of aerospace parts continues to grow, not all aerospace-grade materials are compatible with AM processes Size Constraints Many AM systems have limited build volumes that restrict size of parts that are able to be printed in one piece Certification Challenges Aerospace components require rigorous testing and certification A lack of standardized quality assurance methods for AM parts can slow commercial adoption Standards for traditional manufacturing are well-established, with globally accepted protocols for manufacturers and suppliers Types of Additive Manufacturing in Aerospace Additive manufacturing processes are suitable for specific materials, geometries, and part requirements. AMT identifies 17 distinct AM processes, including a hybrid AM-traditional subtractive machining category, to recognize and bring awareness to the various commercially available 3D printing processes. The ISO/ASTM 52900 standard identifies seven primary AM process categories to standardize terminology and streamline qualification efforts.8,9 The defined AM processes differ in terms of energy source, feedstock form, material compatibility, resolution, build speed, and maximum build volume(s). Commonly used processes for aerospace 3D printing include laser powder bed fusion, directed energy deposition, electron beam powder bed fusion, material extrusion, and binder jetting. The processes and common applications for additive manufacturing in aerospace are detailed below. Laser Powder Bed Fusion (LPBF) The LPBF process uses one or more high-powered lasers to selectively fuse metal powder layer-by-layer to fabricate an object following the design file. Support structures are often required for this process to minimize thermal stresses inherent to the melting process and to expand the potential manufacturable features and geometries. LPBF systems typically operate in an inert atmosphere due to the combustible nature of metal powders. Post-processing steps include excess powder removal, build plate removal, and support structure removal, in addition to optional hot isostatic pressing, surface finishing, machining, or grinding steps. LPBF is commonly referred to as Direct Metal Laser Sintering (DMLS) and Selective Laser Melting (SLM). Directed Energy Deposition (DED) The DED process uses a focused energy source, such as an electron beam, laser, or plasma, to selectively melt material deposited by a nozzle. DED 3D printers are available in wire-arc and powder-based formats, and feedstock material is a metal wire or metal powder. Post-processing may include machining, surface finishing, heat treatment, or inspection based on the specific application requirements. DED is commonly referred to as Electron Beam Additive Manufacturing (EBAM), Wire Arc Additive Manufacturing (WAAM), Direct Metal Deposition (DMD), and Direct Laser Metal Deposition (DLMD) in aerospace applications. Electron Beam Powder Bed Fusion (EBPBF) The EBPBF process uses a high-power electron beam to selectively melt metal powder, according to the part design file using an electromagnetic deflection coil to guide the electron beam. Support structures are rarely required in contrast to LPBF processes. EBPBF systems inherently avoid oxidation issues as they are in a vacuum environment, eliminating the need for inert gas flow. Post-processing for EBPBF includes excess powder removal and may include additional steps such as hot isostatic pressing, surface finishing, machining, or grinding. Material Extrusion (ME) The ME process selectively deposits material through a temperature-controlled nozzle onto the build platform following a design file. Metal, ceramic, polymeric, and plastic composite materials are available for ME 3D printers, typically in a filament or pellet form. A secondary nozzle with water-soluble material may be employed to concurrently deposit support structures to increase the range of manufacturable part features or geometries. Post-processing steps may include support structure removal, debinding and sintering for metals, surface finishing, machining, or chemical treatments. Binder Jetting (BJ) The BJ process begins with a uniform layer of powdered material (metal, ceramic, or polymer) spread across the build platform. One or more nozzle arrays located above the build platform selectively deposit a liquid binding agent onto the powder layer following the part’s design file. The layer-by-layer spreading and depositing steps continue until the part is complete. The loose powder surrounding the bound regions acts as a support structure in each layer. Post-processing includes the manual removal of excess powder and may also require curing or sintering to achieve desired mechanical properties and final dimensions. Table 3: Summary of additive manufacturing processes commonly used in aerospace applications with the correlated AMT classification, ASTM code, aerospace materials, common use cases, benefits, and limitations for aerospace applications. Process AMT Classification ASTM Code8 Aerospace Materials 3,18,19 Use Cases Benefits Limitations Laser Powder Bed Fusion LPBF PBF Ti, Al, and Ni alloys; Cu High-performance metal parts High resolution, high strength High cost, slow printing speed Electron Beam Melting EBPBF PBF Ti alloys, Ni alloys Large structural parts Fast printing speed, low residual stress Lower resolution Directed Energy Deposition DED DED Ti, Stainless Steel, Ni alloys, Cu Repairs, large structures Large format, multi-axis Near-net shape, complicated installation Material Extrusion ME MEX ABS, ULTEM, composite Prototypes, UAV components Affordable Lower strength, lower resolution Sheet Lamination SL SHL Al, Cu, ceramics Embedded electronics Hybrid material builds, low temperature requirements Limited geometries High Speed Sintering HSS BJT Nylon, TPU Complex, lightweight prototypes and cabin components Fast printing speed, easily scalable Surface finish issues Friction Energy Deposition FED DED Ti, Al Large structural parts High deposition rate Near-net shape, niche adoption Binder Jetting BJ BJT Metals, ceramics, polymers Tooling, low-cost metal parts Fast printing speed, easily scalable Requires post-processing Material Jetting MJ MJ Metals, ceramics, polymers Multi-material prototypes High detail, color options for polymers Fragile parts, higher cost Aerospace Additive Manufacturing Materials Materials used in aerospace components need to be lightweight, high-strength, often heat-resistant, and generally dependable under extreme conditions. An expanding range of materials is supported by current AM technologies to address the unique requirements for specific applications within the aerospace industry. Below, we’ve covered properties and aerospace use cases for commonly used materials in aerospace AM, including titanium alloys, aluminum alloys, nickel-based superalloys, copper and copper alloys, polymers and composites, and ceramic materials. Titanium Alloys Titanium and its alloys, especially Ti-6Al-4V, are widely used in aerospace applications due to a high strength-to-weight ratio and high corrosion resistance.6 A main disadvantage of titanium-based parts is an observed decrease in ductility at low temperatures, which can be improved by tuning alloy composition, grain size and phase distribution. Titanium parts are typically manufactured using LPBF, EBPBF, and DED.20 Common Materials: Ti-6Al-4V, Ti-5Al-5V-5Mo-3Cr, Ti-6242 Applications: Structural components, engine parts, brackets, fasteners Aluminum Alloys Aluminum and its alloys are used in a number of AM applications as they are lightweight, corrosion-resistant materials with high thermal conductivity and versatility.6 Common Materials: AlSi12, AlSi10Mg Applications: Airframe components, heat exchangers, UAV parts Nickel-Based Superalloys Nickel-based superalloys are commonly used in high-temperature, high-stress applications, such as jet engine and turbine components. Nickel-based superalloys are known for their high temperature resistance, high creep and fatigue resistance, and corrosion resistance.6 LPBF, EBPBF, and DED are commonly used to produce nickel-based parts for aerospace applications. Common Materials: Inconel, Hastelloy, Haynes Applications: Combustion chambers, turbine blades, exhaust systems Copper and Its Alloys Copper and copper-based alloy parts are attractive for aerospace components due to their high thermal conductivity, strength at elevated temperature, and wear-resistance, but have traditionally been challenging to produce via AM due to heat dissipation, inconsistencies in production of powders, and oxidation susceptibility.3,21 Recent advances in material production and process optimization have addressed many of these challenges, expanding AM’s capabilities to produce copper-based parts, commonly using LPBF, EBPBF, and DED processes.3 Common Materials: Gleen Research Copper (GRCop), GildCop, CuCrZr, C-18150 3 Applications: Wear surfaces, structural components, valves, combustion chamber liners Polymers and Composites Polymeric, specifically thermoplastics, and composite materials are critical in the development of lightweight components. The tunable properties, based on relative ratios of included additives, allow for a higher degree of customization and optimization for specific applications.18 Key advantages of these polymeric materials and composites include thermal insulation and chemical resistance, design flexibility and adaptability, increased durability with reduced mass, and potential for multifunctional systems. Challenges that require further efforts include controlling part shrinkage and warping upon cooling, precision in integration of nanoparticles at the molecular level, and the ongoing need for research to optimize properties and expand applications.18,22 Polymeric parts are typically fabricated using ME, MJ, BJ, or HSS processes. Common Materials: Epoxy resins, Polyimides, Polyetheretherketone (PEEK), Polyetherimide (ULTEM), Carbon nanotube (CNT)-reinforced polymers, graphene-enhanced polymers Applications: Structural and interior aircraft components, thermal protection systems, adhesives, sealants and insulation, flexible or formable aircraft system components Ceramics Ceramics are typically used in niche aerospace applications requiring thermal insulation or wear resistance. Additive manufacturing of ceramics can rapidly produce parts with complex geometries and reduce size shrinkage, while reducing product cost and fabrication time.19,16 Common AM processes for ceramic part production include ME, BJ, and SL.16 Common Materials: Zirconia, Alumina, silicon carbide Applications: Thermal barrier coatings, sensor housings, nozzle linings Trends for 3D Printing in Aerospace The aerospace industry continues to be one of the fastest-growing sectors for AM, due to the need for on-demand, lightweight components, resulting in improved fuel efficiency, and supply chain resilience. Over the past two decades, AM has evolved from prototyping to industrial production, with increasing adoption in aircraft, spacecraft, and UAV systems. Several companies that exhibit at IMTS are leading these trends in the field: Nikon SLM Solutions has partnered with Hexagon (IMTS booth 134102) to produce and validate a flight-capable fuel/air separator for the Airbus 330 aircraft, resulting in a 75% weight reduction of the part from 35 kg to less than 8.8 kg.23 Meanwhile, Nikon SLM Solutions has also partnered with Quintus Technologies (IMTS booth 236430) to develop an Inconel 718 liquid rocket engine combining AM, hot isostatic pressing, and heat treatment, using AM to reduce the thrust chamber component parts from over 100 to 5.24 At the same time, Stratasys’ (IMTS booth 338460) polymer AM is being used on Boom Supersonic’s aircraft, with the company actively marketing its certified flight-grade materials for interior aircraft components.25 Additionally, ZEISS Industrial Quality Solutions (IMTS booth 134302) is providing industrial CT/X-ray metrology services for quality assurance monitoring of 3D printed aerospace components, as part of a five-year research collaboration with Oak Ridge National Laboratory.26 Additive Manufacturing in Aerospace: Exploring the Next Frontier Additive manufacturing continues to expand production of components for aerospace applications, offering lightweight, high-strength parts with complex geometries that improve fuel efficiency, reduce payload, and streamline supply chains. With increasing qualified material options, maturing standardization procedures, and expanding applications in both space and aviation, AM continues to move from niche to mission-critical production. Challenges, including high cost and certification roadblocks remain prevalent. Nonetheless, AM’s growth points towards broader adoption and further integration into aerospace systems. To stay ahead in this rapidly growing field, register for IMTS 2026 – the International Manufacturing Technology Show, which will feature the latest breakthroughs in aerospace additive manufacturing plus hands-on demonstrations from over 1,000 exhibitors. Abbey Knoepfel, Ph.D, is a senior analyst on AMT’s Research team, contributing to AMT's market research in emerging manufacturing technologies with a focus on additive manufacturing. In addition to her research, her degrees in materials science and engineering serve to provide background on the general technical matters included in this article. Learn more about Abbey, and see how your company can benefit from the powerful insights of AMT’s Research team. Related Articles The Superpower of Super Alloys From Tooling to Tubes: The Evolving Promise of DED with Melanie Lang Hyphen Innovations Disrupts Markets With AM Vibration Tech Thriving in Outer Space: The Rosenberg Space Habitat Remembering 9/11: MakingChips Discusses the State of Aerospace & Defense Manufacturing More Additive Manufacturing Articles References (1) Raibole, K. V.; Deshmukh, S. R. Applications and Limitations of Additive Manufacturing Techniques for Manufacturing Components of Aerospace Industry. In Lecture Notes in Mechanical Engineering; Springer Science and Business Media Deutschland GmbH, 2024; pp 11–19. https://doi.org/10.1007/978-981-99-6601-1_2. (2) Careri, F.; Khan, R. H. U.; Todd, C.; Attallah, M. M. Additive Manufacturing of Heat Exchangers in Aerospace Applications: A Review. Applied Thermal Engineering. Elsevier Ltd November 25, 2023. https://doi.org/10.1016/j.applthermaleng.2023.121387. (3) Morshed-Behbahani, K.; Aliyu, A.; Bishop, D. P.; Nasiri, A. Additive Manufacturing of Copper-Based Alloys for High-Temperature Aerospace Applications: A Review. Materials Today Communications. Elsevier Ltd March 1, 2024. https://doi.org/10.1016/j.mtcomm.2024.108395. (4) Bacciaglia, A.; Ceruti, A.; Liverani, A. Towards Large Parts Manufacturing in Additive Technologies for Aerospace and Automotive Applications. In Procedia Computer Science; Elsevier B.V., 2022; Vol. 200, pp 1113–1124. https://doi.org/10.1016/j.procs.2022.01.311. (5) Pereira, T.; Kennedy, J. V.; Potgieter, J. A Comparison of Traditional Manufacturing vs Additive Manufacturing, the Best Method for the Job. In Procedia Manufacturing; Elsevier B.V., 2019; Vol. 30, pp 11–18. https://doi.org/10.1016/j.promfg.2019.02.003. (6) Rodriguez, S.; Kustas, A.; Monroe, G. SAN D2020-7244 Metal Alloy and RHEA Additive Manufacturing for Nuclear Energy and Aerospace Applications; Albuquerque, 2020. http://www.osti.gov/scitech. (7) ADDITIVE MANUFACTURING REQUIREMENTS FOR SPACEFLIGHT SYSTEMS | Standards. https://standards.nasa.gov/standard/NASA/NASA-STD-6030 (accessed 2025-08-13). (8) ISO/ASTM Standard 52900:2021(E). Additive Manufacturing - General Principles - Fundamentals and Vocabulary; 2021. https://www.iso.org/obp/ui/#iso:std:iso-astm:52900:ed-2:v1:en. (9) Chen, Z.; Han, C.; Gao, M.; Kandukuri, S. Y.; Zhou, K. A Review on Qualification and Certification for Metal Additive Manufacturing. Virtual and Physical Prototyping. Taylor and Francis Ltd. 2022, pp 382–405. https://doi.org/10.1080/17452759.2021.2018938. (10) Revolutionizing Aerospace: How Additive Manufacturing is Set to Transform the Industry by 2030. https://www.globenewswire.com/news-release/2025/01/28/3016627/28124/en/Revolutionizing-Aerospace-How-Additive-Manufacturing-is-Set-to-Transform-the-Industry-by-2030.html (accessed 2025-08-07). (11) de Leon, P. G. US 2021/0146606 A1 PRINTER AND PRINTING METHOD FOR SPACE AND PRESSURE SUITS USING ADDITIVE MANUFACTURING, 2021. (12) Pant, M.; Pidge, P.; Nagdeve, L.; Kumar, H. A Review of Additive Manufacturing in Aerospace Application. Revue des Composites et des Materiaux Avances. International Information and Engineering Technology Association April 1, 2021, pp 109–115. https://doi.org/10.18280/RCMA.310206. (13) 3D Printing: Saving Weight and Space at Launch - NASA. https://www.nasa.gov/missions/station/iss-research/3d-printing-saving-weight-and-space-at-launch/ (accessed 2025-08-14). (14) NASA’s Innovative Rocket Nozzle Paves Way for Deep Space Missions - NASA. https://www.nasa.gov/centers-and-facilities/marshall/nasas-innovative-rocket-nozzle-paves-way-for-deep-space-missions/ (accessed 2025-08-13). (15) Stratasys Partners with Top Aerospace and Defense Companies in Development of Newly Qualified Materials for 3D Printing of Mission-Critical Applications :: Stratasys Ltd. (SSYS). https://investors.stratasys.com/news-events/press-releases/detail/938/stratasys-partners-with-top-aerospace-and-defense-companies (accessed 2025-08-13). (16) Dadkhah, M.; Tulliani, J. M.; Saboori, A.; Iuliano, L. Additive Manufacturing of Ceramics: Advances, Challenges, and Outlook. Journal of the European Ceramic Society. Elsevier Ltd December 1, 2023, pp 6635–6664. https://doi.org/10.1016/j.jeurceramsoc.2023.07.033. (17) LEAP Overview - CFM International. https://www.cfmaeroengines.com/leap (accessed 2025-08-25). (18) Jobanpreet Singh; Srivastawa, K.; Jana, S.; Dixit, C.; S, R. Advancements in Lightweight Materials for Aerospace Structures: A Comprehensive Review. Acceleron Aerospace Journal 2024, 2 (3), 173–183. https://doi.org/10.61359/11.2106-2409. (19) Radhika, C.; Shanmugam, R.; Ramoni, M.; Bk, G. A Review on Additive Manufacturing for Aerospace Application. Materials Research Express. Institute of Physics February 1, 2024. https://doi.org/10.1088/2053-1591/ad21ad. (20) Mosallanejad, M. H.; Abdi, A.; Karpasand, F.; Nassiri, N.; Iuliano, L.; Saboori, A. Additive Manufacturing of Titanium Alloys: Processability, Properties, and Applications. Advanced Engineering Materials. John Wiley and Sons Inc December 1, 2023. https://doi.org/10.1002/adem.202301122. (21) Why is copper so challenging to 3D print? - Engineering.com. https://www.engineering.com/why-is-copper-so-challenging-to-3d-print/ (accessed 2025-08-13). (22) Vakharia, V. S.; Leonard, H.; Singh, M.; Halbig, M. C. Multi-Material Additive Manufacturing of High Temperature Polyetherimide (PEI)–Based Polymer Systems for Lightweight Aerospace Applications. Polymers (Basel) 2023, 15 (3). https://doi.org/10.3390/polym15030561. (23) Hexagon and Nikon SLM collaborate to create 75% lightweighting with successful AM A330 Fuel Air Separator prototype production | Hexagon. https://hexagon.com/company/newsroom/press-releases/2024/hexagon-and-nikon-slm-collaborate (accessed 2025-08-25). (24) Nikon SLM Solutions Rocket Combustion Chamber White Paper; 2023. (25) Check Out Stratasys Solutions for Aerospace 3D Printing. https://www.stratasys.com/en/industries-and-applications/3d-printing-industries/aerospace/?utm_source=chatgpt.com (accessed 2025-08-25). (26) ZEISS, ORNL sign licensing agreement for inspection of 3D-printed parts. https://www.ornl.gov/news/zeiss-ornl-sign-licensing-agreement-inspection-3d-printed-parts?utm_source=chatgpt.com (accessed 2025-08-25).
Additive manufacturing in aerospace has rapidly transformed the industry by producing lighter, stronger, and more efficient components that improve performance and reduce lifetime costs. Aerospace 3D printing uses additive manufacturing (AM) to produce components with highly complex geometries while reducing material waste and improving lead times, compared to traditional manufacturing methods.
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