For decades, aerospace engineers have searched for new ways to reduce mass while still keeping everything from wings to engine parts tough enough to handle enormous stresses. Traditional manufacturing methods like forging and machining come with constraints. You can only remove so much material before the part starts losing structural integrity. And sometimes, the part’s shape is dictated more by the limitations of the manufacturing process than by the actual engineering need.

This is where this printing technique for aerospace has made such a big impact. With additive manufacturing, you build a part layer by layer, rather than carving it out of a block. That means you can create hollow interiors, lattice structures, and incredibly precise geometries that simply aren’t possible using subtractive methods. These designs are not only lighter, they’re often stronger too.

You might think of plastic when you hear this term, but in aerospace, it’s all about metals. Titanium, aluminium, Inconel, and stainless steel are among the most commonly used materials. These metals are prized not just for their strength, but for their resistance to heat, corrosion, and fatigue.

Titanium, in particular, has become a superstar in this printing technology for aerospace. It’s as strong as steel but about half the weight. It’s also biocompatible and highly resistant to corrosion, which makes it perfect for everything from aircraft brackets to rocket engine components. Using this method, titanium parts can be built with internal channels and honeycomb patterns that save weight while maintaining rigidity.

Aluminium is another big player. Its lightweight nature and affordability make it a good choice for non-critical structural parts or internal cabin components. Additive manufacturing allows it to be used in far more efficient ways than traditional die-casting ever could.