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3D Printing in Aerospace

The aerospace industry includes a range of commercial, industrial and military applications, and is comprised of departments that design, manufacture, operate and maintain the aircraft or spacecraft. Among the first advocates of 3D printing, the airline industry is a driving force in the evolution of this technology for both manufacturing end-use parts and prototyping. Airlines depend on 3D printing to alleviate supply chain constraints, limit warehouse space and reduce wasted materials from traditional manufacturing processes. Rapidly producing aircraft parts on demand saves enormous amounts of space, time and money.
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3D Printing for Industrial Spacecrafts – NASA

Similarly, an article by Robert Dehue also explains that NASA is using a Stratasys 3D printer to develop and test a space rover. The rover is about the size of a Hummer with a pressurized cabin to support life on Mars and currently contains over 70 FDM 3D printed parts. The 3D printed parts on NASA’s rover include flame-retardant vents and housings, camera mounts, pod doors, a large part that functions as a front bumper and many other customized fixtures.

Stratasys Materials Used for Flight-Ready Parts

ULTEM materials are particularly popular among the aerospace industry because of their resistance to heat and chemicals with a heat deflection temperature around 153 DegreesCelsius (307 Fahrenheit). Using ULTEM in an extremely cold environment is uncommon, but after thorough testing under harsh temperatures and the simulated stresses involved in launching a rocket, ULTEM performed as they hoped. In the end, the team produced a compact inner shell for their freezer units that contained all the mounting structures necessary for mounting in a one-part build. The first freezer units reached the International Space Station in February, 2015 aboard the Falcon 9 SpaceX CRS-5.

Source: Stratasys, International Space Station Freezer with 3D printed liner made of Ultem 9085

Source: Stratasys, International Space Station Freezer with 3D printed liner made of Ultem 9085

Ultem 9085 had also been an invaluable choice for use on satellites. According to NASA, their Jet Propulsion Laboratory found 3D printing to be a much cheaper and quicker alternative to machining custom antenna arrays out of astroquartz, which is a time consuming and very expensive process usually reserved only for larger satellites. The COSMIC-2 (Constellation Observing System for Meteorology, Ionosphere, and Climate) is a medium-sized satellite with 30 antennas used to capture a revolutionary amount of data from GPS and GLONASS that will benefit weather prediction models and research for years to come.

The Future of 3D Printing in Aerospace

NASA and Airbus are just a few examples of how major organizations are turning to 3D printing to solve complex engineering problems and create specialized parts. But what is next on the horizon for 3D printing in aerospace? We’re glad you asked.
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As metal 3D printing advances, we predict vital components of both domestic aircrafts and spaceships will adopt additive manufacturing methods using custom alloys and high-end lightweight thermoplastics. Companies like Boeing are already investing in metal 3D printing companies, like Desktop Metal with the hopes of utilizing these new technologies for research and development as well as end-use-parts for aircraft. With expanding capabilities, 3D printing will be an even more practical solution for aerospace manufacturing.

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