Additive Manufacturing in Aerospace and Defense

To further enhance supply chain resilience, AM fosters a delocalized approach to production. Contract manufacturers who are ITAR registered, like Endeavor 3D, aid in helping defense manufacturers respond swiftly to evolving demand. At Endeavor 3D, we specialize in providing end-to-end additive manufacturing solutions including part design, reverse engineering, polymer and metal production, post-processing, and quality assurance. Our scalable and flexible Multi Jet Fusion (MJF) and Metal Jet technology creates an on-demand  solution, ensuring operational continuity in the face of disruptions.

Additive manufacturing technology has provided a fresh look at how aerospace engineers can manufacture complex parts. By leveraging 3D printing, topology optimization can be used to maximize the efficiency and structural integrity of critical components.

Topology optimization is a mathematical method used to optimize the material layout and geometric features of a part, ensuring the most efficient design and use of resources. To carry out this optimization, the user must specify a design space for the part, apply boundary conditions, and use numerical physics simulation software such as Finite Element Analysis (FEA) or Computational Fluid Dynamics (CFD) to calculate the effect of a representative combination of loads on the part. Once completed, the user will define an objective function that combines several key performance indicators, such as weight, fatigue, and stress, into a single parameter. The optimization algorithm then attempts to maximize this objective function by iteratively changing the part design, either generatively or by varying predefined parameters. During this process, engineers check the effect of its changes on the objective function. When executed correctly, the resulting part will meet its requirements with maximum efficiency and effectiveness.

A practical application for utilizing topology optimization in the aerospace industry is redesigning aircraft brackets. This is a critical component used to attach various systems and structures to the aircraft. For example, the European Aeronautic Defence and Space Company (EADS) Innovation Works optimized the Airbus A320 cabin hinge bracket using AM and topology optimization, resulting in a 60% weight reduction compared to the original structure design.

Furthermore, a study published in Applied Sciences highlights the successful application of topology optimization for an aircraft bracket, resulting in a weight reduction of up to 40% compared to the original design.

When properly executed, topology optimization can produce lightweight and structurally sound aerospace parts. Additive manufacturing presents a convenient way to manufacture the organic geometries common in topology-optimized parts. Due to the layer-by-layer nature of additive manufacturing, the complexity of a part is almost trivial in predicting its cost. Part geometries that require assembly during traditional manufacturing, such as parts with lattice structures or internal passageways, can be produced as a single component. This part consolidation can significantly reduce the bill of materials (BOM) for aerospace and defense components by minimizing the quantity of materials needed for assembly and optimizing material distribution. With recent advances in polymer and metal binder jet 3D printing, topology-optimized parts can be made more cost-effectively, particularly for bridge or low-volume, high-mix production runs.

The National Aeronautics and Space Administration (NASA) has integrated 11 3D printed metal components into the Perseverance Rover a.k.a Percy. Five of the parts make up the shell of the PIXL instrument, a microfocus X-ray tasked with looking for signs of life on Mars. The other six parts are components of the MOXIE heat exchangers which create oxygen.

Lockheed Martin has created the first complex piece of hardware for spaceflight, an omnidirectional antenna for communication relay that has been integrated into a GPS III satellite. This 3D-printed part enables a satellite to communicate with ground systems on Earth. Larry Loh, Director of Engineering Technology and Advanced Manufacturing at Lockheed Martin Space, says, “This process is easily repeatable, which cuts out variabilities in the build and test process. By adopting this technology, we’re able to produce these parts within a tighter range.” Moreover, Lockheed Martin has identified cost savings of around 60% by incorporating additive manufacturing methods into their processes.

The Boeing 777X has incorporated more than 300 3D printed parts into its two GE9X engines. The parts ranged from temperature sensors to heat exchangers, encompassing a wide range of component sizes. Many of the components were made of carbon fiber composites, resulting in a reduction of fuel consumption by 12%.

To extend the life of the existing B-2 bomber, the B-2 Program Office turned to additive manufacturing. The technology was used to create the airframe-mounted accessory drive (AMAD) decouple switch. This component controls the connection of the engines to the hydraulic and generator of the aircraft. The aim was to create an on-demand manufacturing process and reduce operating costs during production. Roger Tyler, an aerospace engineer with the B-2 Program Office, states that, “The B-2 is a low-volume fleet. There are only 20 of them, so anytime something needs to be done on the aircraft, cost can be an issue. But with additive manufacturing, we can design something and have it printed within a week and keep costs to a minimum.”

The aerospace and defense industries are embracing additive manufacturing (AM) to enhance operational efficiency and reduce downtime of legacy aircraft. By integrating advanced design techniques, such as topology optimization and generative design, AM allows for the creation of lighter and more efficient components.

Endeavor 3D stands at the forefront of this efficient approach. As a premier contract manufacturer, our expertise spans both polymer and metal 3D printing technologies, providing a comprehensive suite of services. Our capabilities in reverse engineering and 3D scanning ensure precise replication and enhancement of existing parts. Endeavor 3D’s rigorous quality assurance processes guarantee that every component exceeds industry standards.

Customers partnering with Endeavor 3D gain access to a team of professionals dedicated to crafting customized solutions that align with their specific needs. Our deep understanding of AM, combined with our advanced technological infrastructure, positions us to support dynamic, ongoing collaborations that drive innovation. Whatever stage of the product lifecycle you’re at, Endeavor 3D provides the expertise and resources necessary to cross any production threshold.

Contact a 3D printing expert today to discuss how you can harness the full potential of 3D printing for your next project.