Metal powder bed fusion uses laser or electron beam technology to selectively melt metallic powders layer by layer according to 3D CAD designs. Direct energy deposition processes use focused energy sources to melt materials as they are deposited, enabling repair and coating applications. Post-processing includes heat treatment, machining, and quality inspection to meet aerospace specifications. Advanced materials include titanium alloys, aluminum alloys, and superalloys for high-performance applications.
Enables lightweight designs reducing aircraft fuel consumption by 10-20%, eliminates tooling costs and reduces lead times from months to weeks, and enables mass customization and on-demand spare parts production. The technology reduces material waste and enables complex internal geometries. Additive manufacturing supports distributed production and supply chain resilience.
High equipment costs of $500,000-2 million[1] for industrial systems, slower production speeds than traditional manufacturing for simple geometries, and requires extensive quality control and certification for aerospace applications. Limited material options compared to conventional manufacturing processes. Post-processing requirements add complexity and cost.