European Space Agency to build 3D printed metal parts

The European Space Agency (ESA) is planning to build 3D-printed metal components for use in aircraft, spacecraft and nuclear fusion projects.

The agency’s project called, ‘Additive Manufacturing Aiming Towards Zero Waste & Efficient Production of High-Tech Metal Products (AMAZE)’, aims to use 3D printing or additive manufacturing method to make metal parts that are cost-effective, lighter and stronger than conventional components.

ESA new materials and energy research head David Jarvis told BBC: "We want to build the best quality metal products ever made. Objects you can’t possibly manufacture any other way."

According to researchers, the 3D-printed metal parts for rockets and jets are expected to reduce waste and save money, and the layered method followed during the assembling also allows unique designs, geometries that cannot be achieved through conventional methods.

In an exposition at London’s Science Museum, Amaze researchers have showcased Tungsten alloy parts that can survive temperatures of 3,000°C.

The €20m Amaze project brings together as many as 28 partners, it began in January, with factory sites being set up in France, Germany, Italy, Norways and the UK to develop the industrial supply chain.

With this project, ESA joins the list of countries that are investigating 3D-printing with metal. In July, Nasa successfully tested a 3D-printed rocket engine component and China claims to be manufacturing load-bearing aircraft parts using 3D printing.

General Electric also used the process to make fuel injectors for one of its jet engines.

Amaze researchers have already started 3D-printing metal aircraft engine components and jet wing sections up to 2m in size.

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Image: The Ameze project aims to build metals products for aircraft, spacecraft and fusion projects using 3D-printing method. Photo: courtesy of Suzanne T.