User-Driven Trends for Additive Manufacturing – Aerospace, Automotive, and Healthcare

In 2020, Honeywell’s #4/5 bearing housing became the first FAA-approved 3D-printed safety-critical engine part. While the bearing housing is from a mostly defunct aircraft (the Dassault Falcon 20G), it illustrates that additive manufacturing has met even more of the aerospace industry’s needs and prepares the way for additional flight-critical parts to fly.

As per the news of 2022, the additively created fuel nozzle for commercial airplane engines by General Electric is made with one additive manufacturing component rather than 20 different components, resulting in a 30% cost savings; the new nozzle is 25% lighter and five times more durable.

The RD Limited racing team’s off-road racing vehicle for the 2021 Dakar Rally contains a bespoke gear lever and three titanium brake pedals 3D manufactured. The powder bed fusion method also allowed the researchers to improve the car’s exhaust ball joint design, which is prone to breaking. While only a few pieces were required for the car, these parts have paved the way for additional future 3D printing use cases in greater volume applications.

Porsche is one car manufacturer that has embraced 3D printing. Porsche has a cult following of enthusiasts who build and restore historic Porsche vehicles. Porsche still stocks replacement parts for their historic vehicles, but their stockpile is rapidly depleting. Porsche is now using 3D printing to reproduce nine previously abandoned parts for limited production versions. Porsche 959, 964, and 911 Speedster are among these models.