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.

 

[Mech1595]

Not aerospace, but in my past we were testing 3D printed components intended as direct operational replacement of items utilized in highly energetic environments (vague, I know). Some post-process machining was required in our case, but AM can definitely be a feasible option (application dependent, of course).

 

[CWB1]

I've 3d printed AL engine parts for automotive prototypes that were subject to high stresses on-track and offroad, everything from plumbing fittings and brackets to pulleys and never had a failure. I wouldnt trust them to the public for 300k miles but internally for a few thousand is no problem.

 

[Helepolis]

I've 3d printed AL engine parts for automotive prototypes that were subject to high stresses on-track and offroad, everything from plumbing fittings and brackets to pulleys and never had a failure. I wouldnt trust them to the public for 300k miles but internally for a few thousand is no problem.

Can you elaborate a bit..?
How the cost of 3DP compared to traditional manufacturing?
Did you set-up a printing line at your place or used 3rd party suppliers?
How did you manage to keep the critical geometric and dimensional features (e.g. flatness, parallelism, tight tolerances etc.), the printer was very precise or some post-processing was involved?

 

[Helepolis]

Not aerospace, but in my past we were testing 3D printed components intended as direct operational replacement of items utilized in highly energetic environments (vague, I know). Some post-process machining was required in our case, but AM can definitely be a feasible option (application dependent, of course).

For the printing, did you use 3rd party suppliers or bought your own 3DP setup?

 

[CWB1]

Two of my previous employers owned AL printers. We used them as a cheaper alternative to buying prototype castings. The print quality was excellent so it may not have always been necessary, but I always treated them as a raw casting and had precision surfaces machined after the raw part was printed.

 

[Helepolis]

Two of my previous employers owned AL printers. We used them as a cheaper alternative to buying prototype castings. The print quality was excellent so it may not have always been necessary, but I always treated them as a raw casting and had precision surfaces machined after the raw part was printed.

Do you bay any chance remember the maker and model of the printers?
Can you tell if there were limitations regarding the material type, meaning the printer accepted only one type of alloy, or 6061 could be used?

 

[Mech1595]

For the printing, did you use 3rd party suppliers or bought your own 3DP setup?

Kind of...both? This started as a joint, mutually-beneficial R&D effort between our organization and the original manufacturer of the components, so funding & technical direction was provided by both groups. Success of the project would ultimately result in the manufacturer purchasing more equipment to support full production. Due to the nature of the project, we couldn't just contract the work with any random 3rd party shop.

How did you manage to keep the critical geometric and dimensional features (e.g. flatness, parallelism, tight tolerances etc.), the printer was very precise or some post-processing was involved?

Excellent print quality (WAAM method), but post-processing was required for stress relief & finishing some contact surfaces (e.g. metal-to-metal sealing faces).

 

[Helepolis]

Kind of...both? This started as a joint, mutually-beneficial R&D effort between our organization and the original manufacturer of the components, so funding & technical direction was provided by both groups. Success of the project would ultimately result in the manufacturer purchasing more equipment to support full production. Due to the nature of the project, we couldn't just contract the work with any random 3rd party shop.



Excellent print quality (WAAM method), but post-processing was required for stress relief & finishing some contact surfaces (e.g. metal-to-metal sealing faces).

Did you explore printing with aluminium?