WAAM Solutions
For Aerospace
Large format, low buy-to-fly ratio
Print large structural aerospace parts in one continuous piece, drastically minimizing material waste.
Certified, traceable quality
Rely on a highly qualified production process supported by relevant qualifying frameworks.
Faster than forgings and castings
Reduce lead times for critical, large-scale metal components from months to mere weeks.
WAAM for industry
Aerospace and WAAM
The aerospace and space sectors face immense pressure to accelerate R&D timelines, lighten payloads, and secure vulnerable global supply chains. Large format metal 3D printing for aerospace provides a direct solution, allowing engineers to bypass massive upfront tooling costs and the 12-to-18-month lead times typical of traditional forgings and castings.
By leveraging 3D metal printing, aerospace manufacturers can produce complex components locally and on-demand. If you require structural ground-support hardware or flight-ready components, our industrial metal 3D printing systems for aerospace production offer the scale, speed, and material traceability required to meet the industry’s most rigorous standards.
Our partners
Industry Fit
Why WAAM Works for Aerospace
- Radically Reduced Buy-to-Fly Ratio: Traditional machining wastes massive amounts of high-value aerospace alloys. WAAM deposits material only where needed, cutting material waste by up to 80% on expensive metals like Inconel.
- Topology Optimization & Lightweight Design: WAAM enables engineers to produce complex, organic geometries that reduce overall mass while maintaining structural integrity.
- On-Demand Spare Parts & Obsolescence: Move away from maintaining expensive physical warehouses. Rapidly print obsolete legacy hardware from a secure digital CAD inventory.
- Hybrid Manufacturing & Repair: Print directly onto existing cast or forged substrates, allowing for rapid repairs of worn components or the addition of complex geometric features to standard blanks
Aviation and Space Applications
Aviation
In the aviation sector, the focus is highly structural. Business aviation metal 3D printing is utilized to rapidly produce complex brackets, structural fuselage elements, custom ducting, and urgent on-demand spare parts. These 3D-printed metal aviation components are typically manufactured using high-grade structural aluminum or robust stainless steel, allowing for high-performance lightweighting without sacrificing safety.
Aviation and Space Applications
Space
The space sector demands components capable of surviving extreme thermal and physical stress. Wire Arc Additive Manufacturing (WAAM) is heavily deployed to produce large aerospace components, including launch vehicle hardware, propulsion systems, heavy-duty thrusters, and massive propellant tanks and housings. These aerospace WAAM components primarily utilize heat-resistant superalloys like Inconel 625 and 718 for hot sections, alongside advanced aluminum for structural launch components.
Why Choose MX3D for Aerospace
Turnkey Expertise
We provide complete, plug-and-play M-Series robotic systems powered by our proprietary MetalXL software, delivering a perfectly controlled, ready-to-print industrial cell.
Sustainable Advantage
Significantly lower your manufacturing carbon footprint by eliminating massive material waste and avoiding the shipping logistics of global supply chains.
Proven in Action
Our robust hardware and software have been rigorously tested and deployed in mission-critical, highly regulated environments worldwide.
Get started
Ready to transform your aerospace manufacturing capabilities?
Contact our team of engineers to discuss your next project.
Frequently Asked Questions
Which aerospace components are a good fit for WAAM?
Aerospace WAAM components are typically large-scale, low-to-medium volume metal parts. The most common applications include structural brackets, custom ducting, large propellant tanks, launch support hardware, and robust rocket engine thrusters.
Which alloys are available for aerospace WAAM parts?
We process a wide range of certified aerospace alloys. For high-temperature space applications, we utilize superalloys like Inconel 625 and 718. For structural aviation lightweighting, we print with aerospace-grade aluminum (such as 2319 and 6063), alongside robust stainless steel and super duplex.
What is the difference between WAAM for aviation and space applications?
Aviation applications largely focus on producing structural aluminum brackets, custom ducting, and lightweight spare parts for business aircraft. In contrast, space applications require extreme thermal resistance, utilizing WAAM to print large Inconel thrusters, propulsion housings, and fuel tanks for launch vehicles.
What does the qualification process for metal 3D printed aerospace parts look like?
The qualification process for metal 3D-printed aerospace parts involves strict metallurgical testing, non-destructive testing (NDT), and complete digital traceability of all printing parameters. MX3D systems log extensive real-time sensor data during the build, thereby actively supporting certification frameworks.
Which metal 3D printing methods are used in aerospace, and where does WAAM fit?
The primary metal 3D printing methods used in aerospace are Powder Bed Fusion (PBF) for highly intricate, small parts, and Directed Energy Deposition (DED), specifically WAAM, for large-format components. WAAM is chosen when engineers need to rapidly print structural parts measuring over 500mm using high-deposition rates.
Can WAAM produce large aerospace parts faster than forgings or castings?
Absolutely. By eliminating the need for massive, expensive upfront molds and tooling, WAAM reduces the lead time for producing large-scale structural metal parts from 12–18 months down to just a matter of weeks.
