Aerospace is one of the most demanding industries. Jet engines can burn hotter than a volcano, and spacecraft have to blast through the Earth’s atmosphere. This is why it is so important for parts used in aircraft and rockets to be as strong and reliable as possible.
When creating parts for aircraft, rockets, and spacecraft, manufacturing has to be “smarter.”
Traditional manufacturing requires cutting, shaping, and drilling parts. The process is outdated because it wastes time and resources. Advanced manufacturing, such as metal additive manufacturing or 3D metal printing, can achieve near-impossible levels of precision to build high-quality and strong parts.
Advanced manufacturing pushes engineering boundaries by creating complex shapes and making components faster and lighter. A great example of this is FormAlloy’s metal additive manufacturing system L-DED (Laser Directed Energy Deposition), which is used in aerospace for building, repairing, and enhancing high-performance metal parts.
What makes FormAlloy’s systems so iconic is the incredible accuracy that manufacturers can achieve when building aerospace components. It is literally the reason why aerospace companies can aim higher and higher.
The Shift to Advanced Manufacturing in Aerospace
Advanced manufacturing is ideal for aerospace, as it is a reliable method of production. As of now, manufacturing helps build parts layer by layer instead of carving them out of a metal block. This offers a new level of freedom and precision that sets advanced manufacturing apart from traditional methods.
The aerospace industry is shifting toward advanced manufacturing because of its increased reliability, offering unmatched levels of freedom and precision.
Here are some of the reasons why the industry is moving away from traditional manufacturing to advanced manufacturing:
Weight Reduction
Advanced manufacturing allows aerospace companies to build lightweight parts that are more fuel-efficient and have longer flight ranges.
Complex Geometry
Another reason why advanced manufacturing is preferred in the aerospace industry is the ability to build hollow interiors and shapes that twist and fold. These designs require complicated machining techniques, which advanced manufacturing offers.
Custom, Mission-Specific Components
With the help of advanced automation, you can build custom parts on short notice, which is ideal for aerospace missions.
Rapid Iteration and Fast Innovation
Advanced manufacturing allows engineers to test, tweak, and rebuild parts quickly without taking months, weeks, or even days.
Building High-Performance Parts for Aerospace
Aerospace parts need to be tougher than parts made for any other industry. They have to survive extreme heat conditions so that the aircraft can stay strong during takeoff and even function perfectly at –70°F.
Here’s what makes a part “high-performance” in aerospace:
Strength
Airplanes and spacecraft face intense forces that they must handle, such as pressure, vibration, and heavy loads, without cracking or disintegrating.
Heat Tolerance
Jet engines and rocket nozzles must withstand extremely hot features without warping.
Reliability
Aerospace parts have to be incredibly precise. Even a tiny error in shape or size can affect aerodynamics and render the aircraft unsafe.
How Advanced Manufacturing Meets These Demands Better
Layer-by-layer precision
Metal additive manufacturing ensures precision by building one micro-particle layer at a time. This way, you get all the details needed to achieve precision as well as strength.
Built-in performance features
Advanced manufacturing can create parts with built-in features such as cooling channels, lattice structures, and weight-saving capabilities.
Stronger, more consistent properties
Advanced manufacturing helps minimize welds and joints to create more uniform and stronger parts.
Faster testing and redesign
An engineer can use advanced manufacturing to test different prototypes, revise the design for more innovation, and speed up the production process.
Cost, Speed & Sustainability Benefits
Traditional manufacturing and aerospace innovations were time-consuming processes. This is why advanced manufacturing is a leading solution, which also cuts costs and helps the industry become more sustainable.
Traditional manufacturing can take ages compared to advanced manufacturing. An engineer can design a part and send it for machining only to find that there’s a problem — and the redesign process may take 2 months. This is a slow and expensive process, far more costly than advanced manufacturing.
With the help of advanced manufacturing, an engineer can print a prototype in a day instead of a month. They can design multiple variations to test instantly and even go from remote digital models to physical components.
With additive manufacturing, material is only added where it’s needed, and the process produces near-zero waste for expensive metals like titanium and Inconel. The method is cleaner, sharper, and far more efficient than traditional machining.
The Path to Smarter, High-Performance Flight
Aerospace is entering a whole new era. It is helping build lighter, stronger, and more complex structures. The innovation that advanced manufacturing brings to the table is redefining what is modern for aerospace.
From reducing waste to creating ultra-durable components, advanced manufacturing is repairing high-value parts to ensure aerospace teams experience unmatched flexibility, precision, and control.
If you are ready to explore FormAlloy’s custom aerospace manufacturing systems, contact FormAlloy today for more information.
Frequently Asked Questions
What is advanced manufacturing in aerospace?
Advanced manufacturing uses technologies like metal 3D printing and L-DED to create high-performance aerospace components faster, lighter, and more efficiently than traditional machining.
Why is weight reduction so important in aerospace?
Lighter parts improve fuel efficiency, reduce launch costs, and allow aircraft and spacecraft to carry more payload.
How does advanced manufacturing improve part performance?
It enables stronger geometries, optimized internal structures, and high-precision designs that aren’t possible with conventional methods.
What materials are commonly used in aerospace additive manufacturing?
Titanium, nickel-based superalloys, stainless steel, and high-strength aluminum alloys.
Can advanced manufacturing replace traditional machining?
Not always — but it can complement or outperform it for complex, lightweight, or custom parts.
Is additive manufacturing reliable enough for flight-critical components?
Yes. With proper qualification, testing, and repeatable processes, AM parts meet strict aerospace performance and safety standards.
How does AM reduce production costs?
It cuts material waste, shortens development cycles, and allows repairs instead of full part replacements.
Can advanced manufacturing speed up prototyping?
Absolutely. Engineers can test, refine, and reprint designs in days instead of weeks or months.
What is L-DED, and why is it useful for aerospace?
Laser Directed Energy Deposition builds or repairs metal parts with high precision, making it ideal for large components and high-value aerospace hardware.
How can FormAlloy support aerospace manufacturers?
FormAlloy provides L-DED systems, materials, and engineering support for custom parts, repairs, and R&D innovation.
