Overview
As part of a long-term R&D collaboration, MX3D partnered with Thales Alenia Space to develop a large structural aluminum component. Designed for next-generation manned or unmanned space modules, including advanced pressurized chambers, this component demonstrates how robotic Wire Arc Additive Manufacturing (WAAM) accelerates space hardware production. Pushing the boundaries of MX3D’s continuous R&D, this collaborative effort successfully integrated multi-robot manufacturing, immense part size, and high-performance materials. By replacing traditional forged rings and multi-step assemblies with a single, continuously 3D-printed structure, the project achieved a breakthrough reduction in manufacturing lead times, material waste, and overall supply-chain complexity.
Bypassing Forging Bottlenecks with WAAM
Traditional manufacturing of primary space structures relies on massive raw forgings that carry notoriously long procurement lead times and material waste. Conventional fabrication also requires machining sub-components independently and then joining them, adding multiple production steps. To bypass these bottlenecks, the engineering teams designed multiple sections of the end-product as a single integrated model optimized for large-scale WAAM. The preform was successfully deposited using a high-performance Aluminum-Scandium alloy, eliminating intermediate assembly steps and increasing the near-net-shape factor before external CNC post-machining. Highlighting the industry impact of this collaboration, the completed project was presented at the WAMS 26 conference, organized by ESA and NASA.
Key Project Results
- Lead Time Reduction: Produced the full-scale structure in a fraction of traditional manufacturing times.
- Weight Savings: Substantially reduced the starting raw material mass compared to traditional forging blanks.
- Buy-To-Fly Improvement: Significantly decreased sub-machining material waste.
- Parts Consolidation: Consolidated separate sections into a single print.
“Working at Thales Alenia Space, we are leveraging Wire Arc Additive Manufacturing (WAAM) to rethink how we build large-scale components for space habitats. The milestone achieved was made possible by our collaboration with MX3D.”
— Nicola Aversano, Materials Engineer at Thales Alenia Space
Picture: courtesy of Thales Alenia Space. Post-processing operations performed by supply chain partner for Thales Alenia Space
Project Specifications
- Industry: Aerospace / Space Structures
- Material / Alloy: High-Resistance Aluminum 5183 + Sc (Aluminium-Scandium)
- Dimensions: 3.0 meters diameter x 1.5 meters height
- Print Time: 12 weeks of continuous manufacturing
- Manufacturing Strategy: Robotic WAAM + External CNC Precision Milling
- Key Metric: >50% mass reduction vs. raw forgings, ~60% Buy-To-Fly improvement
Picture: courtesy of Thales Alenia Space. Post-processing operations performed by supply chain partner for Thales Alenia Space
