The aerospace industry is facing profound structural challenges. In addition to shorter development cycles, the focus is increasingly shifting toward weight reduction, material efficiency, and CO₂ emissions reduction. Additive manufacturing processes—particularly metal 3D printing—are seen as a key technology to meet these demands both technically and economically. The Fraunhofer Institute for Laser Technology ILT in Aachen is developing customized solutions such as Laser Powder Bed Fusion (LPBF) and Laser Material Deposition (LMD).
LPBF, whose foundational patent was developed at ILT, enables the production of highly complex components directly from CAD data within just a few days. The process is particularly suited for structural parts with high lightweight potential and offers design freedom while reducing material consumption.
“Wherever tailor-made, highly complex components are required, additive manufacturing can fully exploit its advantages in terms of flexibility,” explains Dr. Tim Lantzsch, head of the Laser Powder Bed Fusion Department at Fraunhofer ILT. “In the aerospace industry, additive manufacturing offers enormous opportunities to optimize components while reducing weight and material usage.”
“The special thing is that we are significantly improving the speed and cost-effectiveness of manufacturing new generations of rocket nozzles thanks to the diverse possibilities of LMD technology. Apart from its large installation space, the design under investigation has exceptionally filigree and thin-walled cooling channels, which can only be manufactured with conventional production routes at great expense,” explains Dr. Thomas Schopphoven, head of the Laser Material Deposition Department at Fraunhofer ILT.
Another research focus is the processing of copper alloys such as GRCop42 using green laser technology. These materials offer high thermal conductivity and are therefore particularly suitable for components exposed to extreme heat, such as rocket engine combustion chambers. The combination of high density and fine-walled structures improves thermal management in demanding operational environments.
“Thanks to precise laser structuring, we can significantly improve the adhesion between metal and plastic and develop hybrid components that are both lighter and mechanically more robust,” explains Dr. Alexander Olowinsky, head of the Joining and Cutting Department at Fraunhofer ILT. “The advantages of processing hybrid materials with laser technology are weight savings, higher strength and durability of the joints, cost savings through low-maintenance joining processes and laser-based repair techniques,” summarizes Olowinsky.
The LMD process is also being used in the European ENLIGHTEN project for the cost-effective production of rocket components with internal cooling structures.
“As aluminum has a high thermal conductivity, welding is traditionally a challenge,” says Thomas Schopphoven. “The adapted LMD process can generate high-strength, precise weld seams that do not place unnecessary stress on the material. This technology is particularly suitable for weight-saving structural elements in aircraft and spacecraft.”
“Together with Airbus Defense and Space in Ottobrunn near Munich, Fraunhofer ILT is developing and building a highly stable transmitter for a LIDAR system for the MERLIN mission that can detect methane in the Earth’s atmosphere,” explains Dipl.-Ing. Hans-Dieter Hoffmann, head of the Lasers and Optical Systems Department at Fraunhofer ILT. “This system makes it possible for the first time to measure the global distribution of methane concentrations in the Earth’s lower atmosphere and their natural and man-made sources with high precision.”
In addition to component production, additive manufacturing also supports the repair and reuse of critical parts. LMD allows for targeted reconstruction of damaged areas—an important step toward sustainable supply chains and low-maintenance repair strategies. In doing so, Fraunhofer ILT is contributing essential impulses for adaptive and resource-efficient manufacturing in the aerospace sector.
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