The European Commission is pursuing ambitious climate targets: The ReFuelEU Aviation Regulation provides for a 60% reduction in CO₂ emissions from aviation by 2050 compared to 1990. These efforts are being supported by the Fraunhofer Institute for Laser Technology ILT in Aachen, which is using new additive manufacturing processes to improve the ecological footprint of the aerospace industry and reduce production costs at the same time.
“Through targeted process adjustments in the laser powder bed fusion process, we can achieve a component density of over 99.5 percent and a high build-up rate of more than 100 cm³/h”, said Luke Schüller, Fraunhofer ILT.
These optimizations enable the production of complex, high-strength components that are both lighter and more resistant – essential properties for future aviation.
Another focus is on laser material deposition (LMD), which, according to Min-Uh Ko, head of the Additive Manufacturing and Repair LMD department, accelerates the production of engine nozzles for the next generation of rockets and makes it more cost-efficient.
“The special thing about LMD is that it drastically improves the speed and cost-effectiveness of manufacturing new types of rocket nozzles”, said Min-Uh Ko, group leader of Additive Manufacturing and Repair LMD at Fraunhofer ILT.
As part of the TIRIKA initiative, the Fraunhofer ILT is working with material manufacturers to develop special powders for hydrogen-powered engines. These aluminum alloys are not only lightweight and high-strength, but also resistant to hydrogen, making them ideal for emission-free drives.
“For us, the life cycle assessment is an indispensable tool for evaluating the environmental impact of products over their entire life cycle and identifying sustainable alternatives,” says Dr. Tim Lantzsch, head of the Laser Powder Bed Fusion department at Fraunhofer ILT.
The EU project ENLIGHTEN, coordinated by the Ariane Group, promotes the development of cost-efficient and environmentally friendly rocket engines. Fraunhofer ILT is working on refining the LMD process and ensuring reliable, controlled production.
Jochen Kittel, project manager of the ENLIGHTEN project at Fraunhofer ILT: “With our process technology, which saves many individual process steps, we can not only substantially reduce costs. At the same time, we are also significantly shortening the production time of a rocket nozzle.”
Additive manufacturing therefore plays a central role in the implementation of EU climate targets and the further development of aerospace technology. By combining innovative materials and precise manufacturing processes, the Fraunhofer ILT is making a significant contribution to the sustainable transformation of the industry.
Min-Uh Ko: “Once we have successfully developed the process and the demonstrator, it will mark a breakthrough. With our results, we can enable the industry, as a supplier to the aerospace industry, to produce equally large, complex and filigree structures on their own systems via LMD in the future.”
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