Opportunities For Additive Manufacturing In Commercial And General Aviation

Report # SMP-AM-AERO-CA-0915
Published September 13, 2015

This report identifies and quantifies the opportunities for 3D printing (3DP) in the commercial and general aviation industries.  It covers jetliners, helicopters, and smaller civilian aircraft and analyzes 3DP’s influence on aerospace manufacturing–and vice versa.

SmarTech believes this unique study will be required reading for marketing, business development and production managers in both the aerospace and 3DP sectors:

  • The commercial aerospace industry is on the cusp of a manufacturing revolution utilizing metal and polymer 3DP technologies to produce aircraft engine components and a variety of structural and cabin components.
  • The number of projects in pre-production and flight testing for aircraft engine manufacturing has grown significantly in just twelve months. GE is no longer the only supplier ramping up for 3DP production. Pratt & Whitney, MTU, Airbus, and others are all integrating final parts into aircraft in volumes that range from hundreds, to thousands, and beyond.
  • Commercial aerospace is the single best example of advancing 3DP as a manufacturing technology rather than just a rapid prototyping tool.

3D printing as a manufacturing technology in aerospace is manifesting itself in several areas, including spare parts manufacturing, experimental flight test parts, remanufacture and repair of existing craft, and on-demand part production of serial components. These represent four of the eight domains of 3D printing utilized in the commercial aerospace industry as identified in this report.

A special feature of the report forms the second chapter of the report, “Interfacing with the Aerospace Industry” in which SmarTech presents input gathered from key aerospace industry professionals over the last 12 months. This chapter details how 3D printing is perceived by various aerospace companies, including their views on key challenges to adoption.

The report the most in-depth market data and forecasts available for 3DP in commercial aerospace market. In this report SmarTech applies its now standard 3DP market models to the study of aerospace, to provide credible 10-year forecasts on various 3DP markets in commercial aerospace.  These forecasts include several hardware categories, print materials, projections for parts printed by aerospace application type, and more.

This report is the companion volume to Additive Manufacturing in Space and Defense Aerospace Markets.  More information on this other volume can be found at https://www.smartechpublishing.com/reports/additive-manufacturing-in-space-and-defense-aerospace-markets

PAGE COUNT FOR THIS REPORT: 118

Chapter One: Adoption of 3D Printing as a Manufacturing Technology
1.1 Introduction to Commercial Aerospace 3D Printing
1.2 Market Factors Influencing 3DP in Commercial Aerospace
1.2.1 Building Value in AM Today Through Small Innovations Key to Growing AM in Step-Change Aerospace Industry
1.2.2 Record Commercial Growth Expected in Various Commercial and Civil Aircraft
1.3 Trends in 3DP Technology Development Influencing Growth in Aerospace Sectors
1.3.1 Build Envelope Expansion
1.3.2 Process Monitoring and Quality Assurance Systems
1.3.3 Remanufacturing Opportunities Utilizing Directed Energy Deposition and Other Technologies
1.3.4 Modular System Design
1.4 Opportunities for 3DP Materials and Services in Commercial Aerospace
1.4.1 Near-Term Opportunities in Materials Favor Metals, Polymers Have Longer Term Potential
1.4.2 Integration of Specialty 3D Printing Service Providers as Aerospace Suppliers to Alleviate Supply Chain Pressure
1.5 Geographic and Competitive Market Considerations for 3DP in Commercial Aerospace
1.5.1 3D Printing Penetration in Total Aerospace Industry Still Leaves Lots of Room for Growth
1.6 Summary of Forecasts for 3D Printing in Commercial Aerospace
1.7 Key Points from This Chapter
Chapter Two: Interfacing with the Aerospace Industry in 2015 
2.1 Current State of AM in Commercial Aerospace
2.1.1 CAD Tool Optimization for Additive Manufacturing of Aerospace Components
2.1.2 Interrelationship Between Space and Defense Markets and Commercial Markets Creating Mutual Benefit for 3D Printing Adoption
2.1.3 Moving Beyond Airplanes
2.2 Developments in Qualifying 3D Printed Parts for Flight
2.2.1 New Non-Destructive Evaluation Methods for 3D Printed Parts
2.2.2 Post Printing Treatment Providing Short Term Solution
2.3 Developments in Applications for 3D Printing in Commercial Aircraft
2.3.1 Polymers Continue to Find Small End-Use Applications
2.3.2 Metals Moving Beyond Aircraft Engines
2.3.3 General Aviation Industry to Benefit from Focus on AM from Commercial Industry
2.4 Extracting Value from Additive Manufacturing in Aerospace
2.4.1 Design Improvements in Aircraft
2.4.1.1 Weight Reduction
2.4.1.2 Increased Performance Characteristics
2.4.1.3 Reduction of Subassemblies
2.4.2 Cost and Lead Time Improvements
2.4.2.1 COGS Improvements
2.4.2.2 Reduction of Total Production Lead Time
2.4.3 Implementation Timelines and Translating Benefits to Aerospace Success Stories
2.4.3.1 Environmental Benefits as a Result of Weight Reduction
2.4.3.2 Easing Pressures of Current Production Schedules through Aggressive Lead Time Reduction via AM
2.4.3.3 Increasing Aircraft Performance through Design for AM
2.4.3.4 Implementation Timelines
2.5 Competitive Implications Resulting from Adoption of AM in Commercial Aerospace
2.6 Key Points from This Chapter
Chapter Three: Review of Existing and Potential 3D Printing Technologies and Applications in Commercial Aerospace 
3.1 3D Print Technologies for Tooling and Design
3.1.1 Material Extrusion
3.1.2 Photopolymerization
3.1.3 Binder Jetting
3.2 3D Print Technologies for Manufacturing
3.2.1 Polymer Powder Bed Fusion
3.2.2 Material Extrusion
3.2.3 Metal Powder Bed Fusion
3.2.4 Directed Energy Deposition
3.3 Review of Applications for 3D Printing in Aerospace
3.3.1 Polymer Applications in Flight Parts and Tooling
3.3.1.1 Electrical Housing Components
3.3.1.2 Tools
3.3.1.3 Environmental Control Systems
3.3.1.4 Cabin Components
3.3.1.5 Total Polymer Application Estimates
3.3.2 Metal Applications in Flight Parts
3.3.2.1 Turbine Blades
3.3.2.2 Fuel Nozzles & Other Engine Components
3.3.2.3 Airframes and Major Structural Components
3.3.3 Metal Remanufacturing Opportunities
3.3.4 Metal Application Summary
3.4 Print Materials for 3D Printing in Aerospace
3.4.1 Metal Opportunities Still Forming, Positive Outlook for Many Categories
3.4.2 Polymer Opportunities Evolving as Transition to Manufacturing Continues
3.5 Summary of Application Opportunities and Key Points
3.6 Key Points from this Chapter
Chapter Four: Major Players in the 3D Printing Aerospace Market 
4.1 3D Printing Technology Vendor Activity in Commercial Aerospace
4.1.1 3D Systems
4.1.2 Arcam
4.1.3 Concept Laser
4.1.4 EOS
4.1.5 ExOne
4.1.6 Fabrisonic
4.1.7 Hunan Farsoon
4.1.8 Matsuura
4.1.9 Sciaky
4.1.10 DM3D (POM)
4.1.11 Stratasys
4.2 3D Printing Material Vendors Influencing Commercial Aerospace
4.2.1 Oxford Performance Materials
4.2.2 Alcoa
4.2.3 AP&C
4.3 Influential Aerospace Companies Advancing 3D Print Technology
4.3.1 Airbus
4.3.2 Boeing
4.3.3 GE Aerospace
4.3.4 GKN
4.3.5 Honeywell Aerospace
4.3.6 Pratt & Whitney
4.3.7 Rolls-Royce
4.4 3D Printing Service Providers Influencing Commercial Aerospace
4.4.1 Materialise
4.4.2 Stratasys Direct Manufacturing (Solid Concepts/Harvest Technologies)
4.4.3 Addaero Manufacturing & Sintavia LLC
Chapter Five: Summary of Ten-Year Forecasts for 3D Printing Opportunities in Commercial Aerospace 
5.1 Discussion of Methodologies
5.2 Summary of Ten-Year Hardware Forecasts
5.3 Summary of Ten-Year Material Forecasts
5.4 Summary of Ten-Year Services and Software Forecasts
About SmarTech Markets Publishing
About the Analyst
Acronyms and Abbreviations Used In this Report 

List of Exhibits
Exhibit 1-1: Framework for Aerospace Manufacturing Innovation
Exhibit 1-2: Penetration of 3DP in the Aerospace Manufacturing Innovation Framework
Exhibit 1-3: Benefits of Modularly Designed AM Systems
Exhibit 1-4: Top Short Term 3D Print Material Opportunities for Commercial Aerospace and General Aviation
Exhibit 1-5: Total Global 3D Printing Revenues, Commercial and General Aerospace, 2014-2024 ($US Millions)
Exhibit 1-6: Total Global 3D Printing Revenues Commercial and General Aerospace, by Region, 2014-2024 ($US Millions)
Exhibit 2-1: Evolving Domains of 3D Printing Exploration in Aerospace
Exhibit 2-2: Current Aerospace Metal AM Workflow Illustration
Exhibit 2-3: Evolution in Polymer 3D Printing Applications in Aerospace
Exhibit 2-4: Implementation Timelines for Achieving Additive Manufacturing Benefits in Commercial Aerospace
Exhibit 2-5: Identified Business Models in 3D Printing Development and Adoption for Aerospace
Exhibit 3-1: Material Extrusion Profile as a Design and Tooling Solution in Aerospace
Exhibit 3-2: Photopolymerization Profile as a Design and Tooling Solution in Aerospace
Exhibit 3-3: Binder Jetting Profile as a Design and Tooling Solution in Aerospace
Exhibit 3-4: Opportunities for Polymer Powder Bed Fusion in Commercial Aerospace Manufacturing
Exhibit 3-5: Evolution of Recently Identified Key Trends in Metal Powder Bed Fusion Systems
Exhibit 3-6: Opportunities for Directed Energy Deposition in Commercial Aerospace Manufacturing
Exhibit 3-7: Projected Polymer Commercial & General Aerospace Parts Printed, by Category, 2014-2024
Exhibit 3-8: Projected Metal Commercial & General Aerospace Parts Printed, by Category, 2014-2024
Exhibit 3-9: Top Short-Term Metal Powder Opportunities for Commercial Aerospace and General Aviation
Exhibit 3-10: Total Estimated Parts Printed in Commercial Aerospace, by Material, 2014-2024 (All Applications)
Exhibit 3-11: Total Estimated Final Use Parts Printed in Commercial Aerospace, by Material, 2014-2024
Exhibit 5-1: Hardware Revenues, by System Category, 2014-2024  ($US Millions)
Exhibit 5-2: Total Space and Defense Aerospace Install Base, 2014-2024
Exhibit 5-3: Total Annual System Sales, By Category, 2014-2024
Exhibit 5-4: Total Annual System Sales, By Technology, 2014-2024  (Units)
Exhibit 5-5: Total 3D Printing Hardware Revenues, by Region, 2014-2024 (US$ Millions)
Exhibit 5-6: Total Material Revenues, by Category, 2014-2024  (US$ Millions)
Exhibit 5-7: Total Material Shipments, by Category 2014-2024 (Kgs)
Exhibit 5-8: Metal Powder Material Shipments, By Type, 2014-2024 (Kgs)
Exhibit 5-9: Metal Powder Material Revenues, By Type, 2014-2024 ($US Millions)
Exhibit 5-10: Total 3D Printing Material Revenues, by Region, 2014-2024 ($US Millions)
Exhibit 5-11: Total 3D Printing Services Opportunities, 2014-2024
Exhibit 5-12: Total 3D Printing Software Revenues, by License Type, 2014-2024 ($US Millions)
Exhibit 5-13: Total Commercial and General Aerospace 3D Printing Service Revenues, by Region, 2014-2024 ($US Millions)


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