New additive manufacturing processes from Fraunhofer ILT can significantly improve the ecological footprint in the aerospace industry and reduce production costs. In the LPBF process (Laser Powder Bed Fusion), metal powder is fused layer by layer with the laser beam. This method enables the production of complex and high-strength components that are not only lighter but also more resistant. In addition, hydrogen is to be used as an emission-free energy source for aviation. To this end, the ILT and its partners have developed special powders that meet the aviation industry's stringent requirements for hydrogen engines. Thanks to the uniform laser melting process, they enable complex geometries and functional structures that cannot be realized with conventional processes such as casting or forging.
Laser metal deposition (LMD) can be used to optimize the production of rocket nozzles; the structures have exceptionally delicate and thin-walled cooling channels that can only be achieved with great effort using conventional production routes. The new process technology also saves many individual process steps, which will enable a significant reduction in costs and shorten the production time of a rocket nozzle.
