3D Printing of Functional Aerospace Prototypes?

[Helepolis]

Hi all,

As the title suggests, I'm exploring the feasibility of manufacturing advanced prototypes (pre-production, for "ground" testing purposes only) of aerospace industry components using 3D printing technology.

The company I work for produces aerospace components (R&D, reverse engineering, and upgrades), specifically focusing on pumps and valves. Many of these pump and valve components are made from aluminum. While aluminum is typically straightforward to machine conventionally, the iterative prototyping process—needed to resolve design issues—can still be lengthy and costly.

I've started considering the possibility of 3D printing relevant parts up to and including the pre-production prototype stage. I am aware that metal additive manufacturing, including aluminum printing, exists, but I currently lack direct experience to determine if it's viable for our purposes.

To clarify my goal: I'm looking to reduce reliance on conventional machining processes—saving lead time and manufacturing costs—by substituting conventional methods with metal 3D printing for pre-production prototypes. Post-processing (finishing machining) could still be used, if necessary, to achieve final tolerances and geometric accuracy. Additionally, it's essential that the 3D-printed parts can undergo live testing within the full assembly, involving actual fluids, pressures, and flow rates.

It's important to note that the 3D-printed parts would not be dynamic components (such as gears, axles, or shafts), but rather static parts such as pump housings, inlet/outlet ports, and similar structural components.

Based on your experience, is it realistic to expect 3D-printed aluminum parts to handle these operational conditions, or am I expecting too much from metal additive manufacturing?

I would greatly appreciate any insights or experiences you can share.

Thank you.

 

[SWComposites]

Yes, it is possible. Already being done by several aerospace OEMs. Aluminum, titanium, steel.
There are several industry committees, ASTM, SAE, etc, working on metal AM standards. You should get involved in those.

 

[rb1957]

sure 3D printing of parts is "disruptive" ... is it "better, faster, cheaper" ? not in the short term, but maybe in the longer term.

I'd like to see 3D printing of bricks in situ from lunar regolith.

 

[IRstuff]

For the purposes of prototyping, 3D AM, particularly for metal parts has been in use, even in my somewhat tiny company, for nearly a decade. Nevertheless, I would not expect the parts to be functionally equivalent, i.e., performance-wise, since structural performance may be compromised, due to the nature of the AM process itself, as well as finish-wise, as you will likely not be able to achieve surface quality nor finish expected from a machined or polished part.

 

[Jboggs]

I would suggest contacting a local university or technical college. Many of them have some pretty high-end 3D printing equipment. I have quotes from a local source for 3D printed metal components. In our case, casting and machining was less costly, but I can see situations where additive metal manufacturing would be feasible.

 

[ctopher]

My son is PhD in material science and did his paper n 3D printing using titanium. He made a jet engine fan blade, works very well.
With metal printing there will be some post machining needed.
The printers are costly. But, depending on quantity of parts it may be worth it.