How Direct Metal Laser Sintering Is Transforming Aerospace Manufacturing

Do you need to quickly produce accurate prototypes and durable end-use components for aerospace applications, without long manufacturing delays? Direct metal laser sintering (DMLS) offers that capability.

High-performance parts for engines

By building metal parts layer by layer from powdered alloys, DMLS lets you realize complex internal geometries that would be extremely difficult to machine using conventional techniques.

GE Aviation’s 3D-printed fuel nozzle tip is a great example. This part includes 14 very detailed fuel passages that help mix jet fuel with air efficiently. The challenge was that the geometry was extremely complex. If you tried to produce the same nozzle using traditional manufacturing, you would have to machine and assemble around 20 separate components. But with direct metal laser sintering, engineers were able to manufacture the entire fuel nozzle as a single piece instead of building it from many smaller parts, simplifying production and removing much of the assembly work. The redesigned nozzle also ended up being about 30% cheaper to produce. It became lighter and stronger, and more efficient in operation.

Lightweight yet strong structural components

Metal 3D printing also lets you create structural parts that maintain strength while reducing overall weight. By reducing aircraft weight, you can improve fuel efficiency and reduce emissions, making this direct metal laser sintering especially valuable in aerospace design.

Airbus demonstrated this advantage with its ‘bionic partition,’ which separates the passenger cabin from the galley. Using advanced alloy and metal 3D printing, Airbus reduced the partition weight by around 45% without sacrificing structural integrity.

Rapid development

Metal 3D printing can also help you develop and produce new high-performance alloys more efficiently, as you can see with NASA’s GRX-810 alloy. Engineers developed it to produce aerospace parts that can handle temperatures above 1,093 °C while still staying durable and strong. The material is twice as strong, three times as flexible, and up to 1,000 times more durable than many existing high-temperature materials.

With metal 3D printing, you can produce and test metal parts such as this much faster than with conventional manufacturing techniques. This shorter development cycle lets you evaluate new alloys quickly and refine them at a lower cost.

Need DMLS for your aerospace projects?

HLH Prototypes is ready to support your project with its direct metal laser sintering service.

If you are unsure whether DMLS suits your design, their specialists can review your project requirements and recommend the best manufacturing approach. Contact HLH Prototypes for a free project review and learn how their service can help you produce precise and durable aerospace parts.

About the Author

HLH Prototypes Co. Ltd. offers high-quality rapid prototyping, CNC machining, 3D printing, and injection molding services. Trusted globally, they deliver precision-engineered parts and product development solutions with fast turnaround times and excellent customer support.

HLH Prototypes Co. Ltd. Provides rapid part manufacturing solutions like 3D printing, CNC machining, rapid tooling, rapid injection molding, and SLS 3D printing service, vacuum casting (urethane), and sheet metal work.