Metallurgy Additive Manufacturing for Aerospace: Market Shares, Strategies, and Forecasts, Worldwide, 2017 to 2023

 Table of Contents

Additive Manufacturing For Aerospace Executive Summary 16
Additive Manufacturing for Aerospace Market Driving Forces 16
Additive Manufacturing for Aerospace Market Shares 20
Additive Manufacturing for Aerospace Market Forecasts 22

1. Additive Manufacturing For Aerospace: Market Description And Market Dynamics 25
1.1 Aerospace Additive Manufacturing (AM) Process 25
1.2 3D Metallic Printing for Aerospace 27
1.2.1 EBM® in Aerospace 27
1.3 Designing Value into Additive Manufacturing 28

2. Additive Manufacturing For Aerospace Market Shares And Forecasts 30
2.1 Additive Manufacturing for Aerospace Market Driving Forces 30
2.2 Additive Manufacturing for Aerospace Market Shares 34
2.2.1 Bright Laser Technologies 38
2.2.2 GE 39
2.2.3 Benefits of GE Aerospace Additive Manufacturing Acquisitions 40
2.2.4 GE Seeks To Have Its Additive Manufacturing Business Achieve $1 Billion In Revenue by 2020 41 2.2.5 Desktop Metal Technology 42
2.2.6 Höganäs Group / Digital Metal 43
2.2.7 Lockheed Martin 43
2.2.8 Sciaky Big Metal Experts: 44
2.3 Additive Manufacturing for Aerospace Market Forecasts 45
2.4 Metallurgy Additive Manufacturing for Aerospace Market Challenges 49
2.5 Metallurgy Additive Manufacturing for Aerospace Market Segment Forecasts 50
2.5.1 Metallurgy Additive Manufacturing for Aerospace Applications 52
2.5.2 Additive Manufacturing Materials 54
2.6 Market Forecast Additive Manufacturing, Market Segment Analysis 56
2.7 Additive Manufacturing for Aerospace Pricing 57
2.8 Additive Manufacturing for Aerospace Regional Segment Analysis 58
2.8.1 US Metallurgy Additive Manufacturing For Aerospace Market 60
2.8.2 Significant Regional Growth In Metal Additive Manufacturing in Asia 61

3. Additive Manufacturing For Aerospace Product Description 62
3.1 3D Systems Aerospace and Defense Metallic Additive Manufacturing 62
3.1.1 3D Systems DMP Printers 62
3.2 Digital Metal 63
3.3 GE 3D Metallurgy Printing in Jet Engines 64
3.3.1 GE Arcam EBM 68
3.3.2 GE Arcam EBM® — Electron Beam Melting 71
3.3.3 Additive Manufacturing (AM) at GE Additive 77
3.4 Ancor AM Powders 79
3.5 Metallurgy Additive Manufacturing at NASA 79
3.6 3D Metallurgy Printing at SpaceX 82

4. Additive Manufacturing For Aerospace Research And Technology 90
4.1 3D Printing Set To Revolutionize Manufacturing Processes Involving Metals 90
4.1.1 3D Printing Of High-Strength Aluminum Alloys 91
4.1.2 Nanoparticles of Nucleants Used To Resolve Melting And Solidification Dynamics 92
4.1.3 Selective Laser Melting Creates Grains Roughly Equal In Length, Width And Height 92
4.2 Microstructure and Mechanical Properties of Aerospace Metallic Components and Parts 93
4.3 Additive Manufacturing of Titanium Alloy for Aerospace Components 94
4.4 High-Strength Nickel Based Superalloy Metal AM Rocket Engine ProjectX 98
4.5 Most Effective Size Range for EBAM Parts 99

5. Additive Manufacturing For Aerospace Company Profiles 102
5.1 3D Systems 102
5.1.1 3D Systems Teams with Airbus Defence and Space to Produce Metal AM satellite RF Filter 104
5.1.2 3D Systems Revenue 106
5.2 Aerojet Rocketdyne 113
5.2.1 Aerojet Rocketdyne Breaks Ground Advanced Manufacturing Facility in Huntsville 115
5.3 Airconic 117
5.4 Airbus 118
5.5 Alcoa 119
5.6 American Standard 119
5.7 BASF 120
5.7.1 BASF SLM Solutions 123 5.8 Boeing 124
5.8.1 Boeing AM Advantages 126
5.9 Bright Laser Technologies 132
5.10 Carpenter Technology 135
5.11 Cerevo 136
5.12 CFM International 137
5.12.1 CFM $1.0 Billion Leap-1a Engine Order from Cathay Pacific Places 138
5.13 Concept Laser 140 5.14 Desktop Metal -- 141
5.14.1 Desktop Metal Partners with Morris Group for Distribution 142
5.15 DMG Mori 142
5.16 EOS 143
5.17 Farsoon 144
5.18 GE 145
5.18.1 Formation of GE Additive: Aviation’s Acquisition of Metal 3D Printer Manufacturers Concept Laser and Arcam145
5.18.2 GE / Arcam AB 145
5.18.3 GE Arcam Drivers for Additive Manufacturing 147
5.18.4 GE AP&C State-Of-The-Art Powder Manufacturing Facility in Canada 148
5.18.1 GE / Concept Laser 148
5.18.2 GE AM Fuel Nozzle 149
5.18.3 Concept Laser 156
5.19 Hewlett Packard 159
5.20 Höganäs Group / Digital Metal 159
5.20.1 Honeywell Aerospace and Digital Metal Exploring Joint AM Projects 160
5.20.2 Digital Metal Adds Titanium To Stainless Steels 161
5.21 Honeywell 161
5.21.1 Honeywell Powder Materials 163
5.22 Kymera 165
5.23 Lockheed Martin 165
5.24 Lumex 167
5.25 Markforged 168
5.26 Materialise NV 171
5.27 NanoSteel 172 5.28 NASA 172
5.29 Norsk Titanium 175
5.29.1 Norsk and Spirit 175
5.30 Optisys 177
5.31 Phoenix Scientific Industries Ltd (PSI), 178
5.32 Praxair Powders 178
5.33 Renishaw 179
5.34 Sciaky 180
5.34.1 Sciaky’s Electron Beam Additive Manufacturing (EBAM) 181
5.34.2 Sciaky Imaging And Sensing System Provides a Closed-Loop Control 182
5.34.3 Sciaky EBAM Dual Wire Feed System 182
5.35 Siemens 183
5.35.1 Siemens / Materials Solutions 183
5.36 SpaceX 186
5.36.1 SpaceX Iridium-3 Mission 189
5.36.2 SpaceX Printed Part To Space, Creates Printed Engine Chamber 189
5.37 H.C. Starck 192
5.37.1 H.C. Starck Amberprint 193
5.38 Stratasys World Leader in 3D Printing 195
5.38.1 Stratasys Direct Manufacturing Selected by Airbus to 3D Print Polymer Serial Flying A350 XWB Parts 196
5.38.2 Stratasys Defining Force in 3D Printing And Additive Manufacturing 197
5.38.3 Stratasys Releases First Quarter 2017 Financial Results 197
5.39 Tekna Group 203
5.39.1 Tekna Manufacturing High-Quality Metal Powders For Additive Manufacturing Applications In Aeronautics And Space 203
5.40 Thales 205
5.41 Titomic 206
5.41.1 Titomic Ltd, Commercializing A Process For The Additive Manufacturing Of Large Scale Titanium Parts 206
5.42 Trumpf adds Fraunhofer’s Extreme High-Speed Laser Deposition Welding Process 208
5.43 United States Metal Powders 209
5.44 Voestalpine AG 210
5.45 List of Selected Metal Additive Manufacturing Companies 211
Wintergreen Research, 220
WinterGreen Research Methodology 221

List of Figures

Figure 1. Additive Manufacturing for Aerospace Market Driving Forces 16
Figure 2. 3D printing Metallurgy Additive Direct Digital Manufacturing Benefits 17
Figure 3. Benefits of Choosing EBAM for Additive Manufacturing Process 18
Figure 4. Metallurgy Additive Manufacturing Aerospace Market Shares, Dollars, Worldwide, First Three Quarters 2017 21
Figure 5. Metallurgy Additive Manufacturing Aerospace Market Shipments Forecasts Dollars, Worldwide, 2017-2023 24
Figure 6. Aerospace Additive Manufacturing (AM) Technology Challenges 25
Figure 7. Aerospace Additive Manufacturing (AM) Technology Development Opportunities 26
Figure 8. Additive Manufacturing for Aerospace Market Driving Forces 30
Figure 9. 3D printing Metallurgy Additive Direct Digital Manufacturing Benefits 31
Figure 10. Benefits of Choosing EBAM for Additive Manufacturing Process 32
Figure 11. Metallurgy Additive Manufacturing Aerospace Market Shares, Dollars, Worldwide, First Three Quarters 2017 35
Figure 12. Metallurgy Additive Manufacturing for Aerospace, Printers and Tooling, Market Shares, Dollars, Worldwide, First Three Quarters 2017 36
Figure 13. Bright Laser Technologies 38
Figure 14. Benefits of GE Aerospace Additive Manufacturing Acquisitions 41
Figure 15. Metallurgy Additive Manufacturing Aerospace Market Shipments Forecasts Dollars, Worldwide, 2017-2023 46
Figure 16. Metallurgy Additive Aerospace Manufacturing Market Forecasts, Dollars and Units, Worldwide, 2017-2023 47
Figure 17. Metallurgy Additive Manufacturing For Aerospace Market Challenges 49
Figure 18. Metallurgy Additive Aerospace Manufacturing Market Segments, Airplane Engines, Government and Defense, and Space, Forecasts, Dollars and Units, Worldwide, 2017-2023 51
Figure 19. Metallurgy Additive Manufacturing Market Segment Forecasts Dollars and Units, Worldwide, 2017-2023 56
Figure 20. Metallurgy Additive Aerospace Manufacturing, Regional Market Segments, 2017 58
Figure 21. Metallurgy Additive Aerospace Manufacturing, Regional Market Segments, 2017 59
Figure 22. Digital Metal DM P2500 3D Printer 63
Figure 23. CFM International’s 3D-Printed Fuel Nozzle for GE Jet Engines 65
Figure 24. GE Jet Engine Nozzles 3D Printing Improvements 66
Figure 25. GE LEAP A1 Jet Engine 67
Figure 26. GE Arcam EBM® — Electron Beam Melting Arcam EBM® Systems Architecture 70
Figure 27. GE Arcam Q20plus 3D Printing Chamber 72
Figure 28. GE Arcam EBM® — Electron Beam Melting Features 74
Figure 29. GE Arcam Q20plus Aerospace Low Pressure Turbine Blade Component Example 75
Figure 30. GE Arcam Q20plus Specifications Designed For Cost-Efficient Production Of Aerospace Components 76
Figure 31. Ancor AM Powders 79
Figure 32. Combustion Chamber Developed By Engineers At NASA's Marshall Space Flight Center In Huntsville, Alabama, For An Additively Manufactured Demonstration Engine 80
Figure 33. NASA Metallurgy 3D-Printed Rocket Engine Components 81
Figure 34. Spacex Launches 3d-Printed Part To Space, Creates Printed Engine Chamber 83
Figure 35. SpaceX Test Firing the Raptor Engine 84
Figure 36. SpaceX Printed Engine Chamber 85
Figure 37. SpaceX Raptor System with 40% 3D Printed Parts 86
Figure 38. Airbus to Receive 3D-Printed Fuselage and Engine Pylon Parts from Alcoa 87
Figure 39. Alloys That Work for 3D Metallurgic Printing 91
Figure 40. Aluminum Alloy Powders 92
Figure 41. Titanium Alloy Specifications 95
Figure 42. Applications for Titanium Ti6Al4V: 96
Figure 43. GE Arcam Titanium Ti6Al4V (Grade 5) Powder Specification 96
Figure 44. Machining Ti6Al4V Parts Manufactured in the EBM Process 97
Figure 45. Australian Team Tests Metal AM Rocket Engine 98
Figure 46. ProjectX Engine During A Test Fire, Shock-Cell Structure In The Rocket Plume Is Visible 99
Figure 47. System Process Components for the Build Industry Specifications 101
Figure 48. 3D Systems ProX DMP 320 Metal Printer 103
Figure 49. 3D Systems Metal Additive Manufacturing Applications 105
Figure 50. 3D Systems Revenue 112
Figure 51. Aerojet Rocketdyne Advanced Manufacturing Facility in Huntsville 116
Figure 52. Aerojet Rocketdyne 3D Printed Rockets 117
Figure 53. Airbus to Equip A350 XWB Pylon with 3D Printed Bracket 118
Figure 54. Airbus to Receive 3D-Printed Fuselage and Engine Pylon Parts from Alcoa 119
Figure 55. BASF Ultrafuse 316LX Additive Manufacturing For Fused Filament Fabrication Of Metal Parts 121
Figure 56. Boeing FA-18E Super Hornet 124
Figure 57. Boeing F-15 127
Figure 58. Boeing 777x, Comparative wingspans 128
Figure 59. Boeing Norsk Titanium AS to Print 787 Parts 128
Figure 60. Norsk Titanium's MERKE IV Rapid Plasma Deposition™ 3D Printer Creating An Aircraft Part 131
Figure 61. Bright Laser Technologies 132
Figure 62. Bright Laser Technologies Research Center 133
Figure 63. Bright Laser Technologies Aerospace Metallic Parts 134
Figure 64. Bright Laser Technologies Aerospace Fuselage Structure Parts 135
Figure 65. Cerevo Bicycle Frame 136
Figure 66. Cathay Pacific Places $1.0 Billion Cfm Leap-1a Engine Order 139
Figure 67. EOS Metal Additive Manufacturing 144
Figure 68. CFM International’s 3D-Printed Fuel Nozzle Reduces Part Count 151
Figure 69. Additive Manufacturing, 3-D Printing 154
Figure 70. AM Let GE Aviation Reduce The Weight Of The Engine By 5 Percent 155
Figure 71. Concept Laser Manufactures The Largest Powder Bed Fusion Metal 3d Printer On The Market, The X Line 2000R 157
Figure 72. GE Additive Manufacturing Disruptive Technology: Changing the Product Development and Manufacturing 158
Figure 73. Honeywell HTF7000 Engine In Production at Honeywell’s Phoenix Facility 162
Figure 74. Honeywell’s Phoenix Additive Manufacturing Technology Centre, 163
Figure 75. Honeywell Inconel 718 Engine Mount Bracket 164
Figure 76. Markforged Metal X 3D Printed Metal Components. 169
Figure 77. Markforged Target Industries 170
Figure 78. NASA Additive Manufacturing Operations 174
Figure 79. Norsk Provides Titanium to Spirit that Builds Thousands Of Titanium Parts For Customers Around The Globe 176
Figure 80. Optisys Extreme Parts Consolidation Of Antenna Systems Enables Reduced Size, Weight, Lead Time And Cost While Boosting RF Performance 177
Figure 81. Praxair Surface Technologies Metal Powders Functions 178
Figure 82. Sciaky Offers 3D printing 180
Figure 83. EBAM® Process 181
Figure 84. Siemens Metals Additive Manufacturing for Aerospace 183
Figure 85. Siemens 2017 Capacity 184
Figure 86. Markforged Metal X 3D Printed Metal Components. 185
Figure 87. SpaceX Liftoff 187
Figure 88. SpaceX Iridium-3 Mission 189
Figure 89. SpaceX Falcon 9 Rocket Launch 190
Figure 90. SpaceX 3D Printed Engine Chamber 191
Figure 91. H.C. Starck Surface Technology and Ceramic Powders GmbH Amberprint 193
Figure 92. H.C. Starck Surface Technology and Ceramic Powders GmbH Aerospace Powders 195
Figure 93. Stratasys Recent Business Highlights: 198
Figure 94. Stratasys Milestones Towards Adopting Additive Manufacturing In Complex Requirement Applications: 200
Figure 95. Stratasys Smart Multi-Cell System 201
Figure 96. Stratasys Metal Initiatives 202
Figure 97. Tekna Manufactures Turnkey Plasma Systems To Make High Quality Spherical Powder 204
Figure 98. Tekna High Quality Titanium Spherical Powder Properties and Powder SIze 205
Figure 99. Titomic TKF Titanium Rapid AM Process 207 

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