Aerospace Additive Manufacturing Market Set for Takeoff: Growth Drivers and Emerging Opportunities to 2035
A rigorous research lens on aerospace additive manufacturing (AM) must dig into technologies, breakthroughs, industry players, and white spaces. Using the MRFR report as a backbone, here’s a research-oriented exploration.
Core Technologies & R&D Directions
The aerospace AM domain is grounded in several key technologies: laser sintering, 3D printing, electron beam melting (EBM), fused deposition modeling (FDM), and stereolithography. Each has different material compatibilities and precision/throughput tradeoffs.
Metal AM (e.g. EBM, laser sintering): Often a focal R&D area given the demand for high-temperature, high-strength parts (e.g. engine components).
Polymeric/FDM processes: Useful for non-structural, interior, or ducting parts where mechanical loading is lower.
Hybrid & Multi-material Research: Combining additive methods with subtractive finishing (machining) or embedding sensors is an active frontier.
AI & Process Monitoring: Researchers are embedding real-time monitoring, defect detection, and closed-loop control in AM lines, enabling better yield and reliability.
Key Industry Players & Their Research Strategies
Leading firms profiled by MRFR include Arcam AB (GE Additive), 3D Systems Inc., CRP Technology, Concept Laser (GE), EOS, Stratasys, Optomec, SLM Solution, and others. Their research strategies often include:
Vertical integration of materials (e.g. making their own powders)
Collaborative development with aerospace OEMs
Product launches targeting serial production (vs. prototyping)
Mergers & acquisitions to absorb niche capability (e.g. GE Additive’s integration of Concept Laser and Arcam)
Research Gaps & Challenges
Certification, Testing & Standards
One of the thorniest gaps is the absence (or slow evolution) of consistent, globally accepted standards for additive parts in aerospace. Long-term fatigue, thermal cycling, and safety validation remain challenging research domains.
High-Performance Materials
While metal alloys dominate, there is still need for novel materials (e.g. high-temperature superalloys, composites, ceramic-metal hybrids) that are fully AM-compatible. Research here is intensive but not yet mature.
Scale & Throughput
Research is needed to scale AM to large, complex components without sacrificing quality. Current constraints include build size limits, residual stresses, and part post-processing.
Process Repeatability & Yield
Ensuring batch-to-batch consistency, minimizing defects (porosity, delamination), and improving yields is ongoing. Research into in-situ monitoring, feedback control, and predictive modelling is key.
Cost Reduction
To make AM cost-competitive, R&D must target reductions in machine cost, powder recycling, energy consumption, and post-processing.
Emerging Research Themes
Cryogenic & Propellant Tanks for Hydrogen Aircraft
The MRFR report cites a recent development: Spain’s AIMEN Technology Centre created a 3D-printed cryogenic tank demonstrator for liquid hydrogen storage in aircraft, under the European OVERLEAF project. This points to novel research combining structural AM and cryogenic containment.
Electronics-Embedded AM Parts
Integrating sensors, wiring, and electronics within the AM build, enabling “smart components” that sense stress or temperature in situ.
Binder Jetting Advances
Some players (e.g. GE Additive) are working on binder-jet metal printing to enable higher throughput. MRFR notes forthcoming GE Additive Binder Jet and Series 3 developments.
Adaptive & Generative Design Algorithms
Coupling generative design (topology optimization) with AM to yield organic, performance-driven shapes.
Research Impact & Potential
As research in these areas matures, we can expect:
Faster certification of more complex AM parts
Broader adoption in structural and engine domains
Expansion of AM into new applications (cryogenics, propulsion systems, intelligent structures)
Economies of scale that reduce cost barriers and democratize access
Conclusion
While the aerospace AM market outlook is strong, the strength of the actual outcome will depend heavily on research advances in materials, process repeatability, scale, and regulatory frameworks. The players who lead in bridging those gaps will likely shape the future of aircraft manufacturing.