rapid.tech 3D discusses AM applications in aerospace

Additive manufacturing is playing an increasingly important role in the aerospace industry. The rapid.tech 3D Aerospace Forum on May 13, 2025 will focus on innovative and economical applications of additive manufacturing (AM). Experts from industry and research will present current developments, including qualified components for space missions and aircraft systems.

A key aspect of the forum is the efficiency of AM in the aerospace industry. In an industry where weight savings and functional integration are crucial, additive manufacturing offers design freedoms that would be difficult to implement using conventional methods. At the same time, the technology must be economically viable, as manufacturing costs and certification efforts are high, especially for low volumes.

“To put it simply, aerospace is always about achieving flight with the lowest possible weight and high functional integration in the smallest possible installation space. Additive manufacturing can provide innovative solutions here that are not feasible with conventional technologies. But: AM must also be profitable, especially in view of the necessary qualification and certification. This means that with the often very small quantities – especially in aerospace – the first attempt must be successful immediately. The focus in the Aerospace Forum is therefore clearly on applications that offer the user added value and have already proven this in practice,” explains Stephan Eelman, Head of Strategy for Europe at Boeing.

One key topic is the use of AM in aerospace. Fraunhofer EMI, for example, will be presenting the additive manufacturing of components for the German nanosatellite ERNST, which is used for military surveillance tasks. The Ariane Group will also be reporting on the successful use of additively manufactured components in the Ariane 6 launch vehicle. One example is the Auxiliary Power Unit (APU), which was produced using laser beam melting. The complex design of this unit could only be realized with AM and contributes to the functionality of the upper stage of the rocket.

In aviation, the focus is on material and process-specific developments. Liebherr-Aerospace will be presenting an additively manufactured hydraulic component whose manufacturing process will be traced from the design phase through to aviation approval. In addition, CHESCO, in collaboration with Rolls-Royce Germany, will show how it has succeeded in manufacturing combustion chamber segments from Haynes 282 without support structures – an optimization that simplifies production processes and reduces material usage. Materialise discusses the progress of polymer AM in terms of sustainability, while Howmet Tital presents alternative metallic processes for the aviation industry.

“This example illustrates a new trend in the development sector. In combination with AI, digitalization technologies such as digital twins or the creation of digital product passports, we can open up further potential for innovative, economical and reliable AM solutions in the aerospace industry,” emphasizes Stephan Eelman.

In addition to new developments for new aircraft, the optimization of existing aircraft models using AM technologies will also be examined. Pioneer Aeronautics Innovation (PAI) shows an example of AI-supported optimizations of wingtips of existing aircraft, which enable a significant weight reduction and an improvement in aerodynamic efficiency. The use of additive manufacturing techniques has enabled both manufacturing costs and fuel consumption to be reduced.

The forum also offers space for a direct exchange with the speakers. In an open plenary session, participants can ask specific questions about the presentations. In addition to aerospace, rapid.tech 3D will also cover other areas of application for additive manufacturing. Additional forums will be dedicated to topics such as robotics, mobility, chemical and process engineering and electronics. Quantum Photonics, which deals with the interfaces between additive manufacturing and quantum technologies, will also take place parallel to the trade fair.