GKN, Materialise further additively manufactured aviation parts certification

Aerospace technology company GKN Aerospace (Redditch, U.K.) and Materialise (Leuven, Belgium), known for its 3D printing solutions and services, have signed a letter of intent (LOI) aimed at advancing the research, design, and production of polymer additively manufactured (AM) parts for the aviation industry. According to Materialise, powders (selective laser sintering) and filaments (fuse deposition modeling of thermoplastics) will be initial materials studied — but as part of its joint R&D efforts, in collaboration with GKN’s Global Technology Center in Hoogeveen, Netherlands, the company also has the potential to consider hybrid solutions at a later stage, such as the use of fiber reinforcement.

The LOI, which was signed at the Paris Air Show 2023 represents an extension of both companies’ successful collaboration. Materialise has been a supplier of polymer additive manufacturing (AM) to GKN Aerospace since 2015, and supported the delivery of the additively manufactured wingtip for Eviation’s (Qadima, Israel) Alice all-electric aircraft, which made its maiden flight in 2022.

Together, GKN Aerospace and Materialise aim to accelerate the certification of the AM process and push the boundaries of additive production of functional and flight-critical aerostructures. The collaboration ranges from prototyping to the production of functional and flight-critical parts, aligning with the industry’s emerging sustainability trends and opportunities. In particular, the partnership will focus on electric vertical takeoff and landing (eVTOL) aircraft.

“This alliance aims to leverage our combined expertise and the exceptional benefits of 3D printing to push the boundaries of innovation in the aeronautics industry,” says Jurgen Laudus, vice president of Materialise Manufacturing. “Together, we aim to drive technological advancements, respond more effectively to customer requirements, and shape the future of aerospace manufacturing.”

The potential of AM to revolutionize the aviation industry is said to be significant, with the creation of lighter and stronger parts that were previously unachievable with conventional manufacturing technologies, while offering time and cost reductions during the manufacturing process.

GKN Aerospace and Materialise bring complementary manufacturing experience across multiple AM printing technologies. Materialise, with more than three decades of experience, pioneers the production of certified parts for various industries and provides EASA 21.G-certified flying parts, software solutions and consultancy services for the aerospace industry. GKN Aerospace, a global technology leader in AM, has load-bearing AM structures certified and in serial production, as well as numerous other AM parts flying today for commercial, military, rotorcraft and space applications.