Fraunhofer ILT, based in Aachen, Germany, is spearheading sustainable aerospace advancements by leveraging 3D printing to meet European Union regulations on environmental impact. Through the TRIKA (Technologies and Innovations for Resource-saving, Climate-friendly Aviation) initiative, Fraunhofer ILT is developing metal powders for laser powder bed fusion (LPBF) tailored for emission-free hydrogen rocket engines. These materials enable the creation of lightweight engine components specifically suited to hydrogen propulsion, aiding aerospace companies in meeting strict EU requirements for cleaner aviation technology.
Fraunhofer ILT is also conducting life cycle assessments (LCAs) to evaluate the environmental and cost benefits of using LPBF 3D printing in aerospace, a process that Dr. Tim Lantzsch, Head of the LPBF department at Fraunhofer ILT, considers essential for sustainability. Additionally, the research organization is working to improve rocket component production with laser material deposition (LMD) 3D printing. This technique aims to streamline the production of rocket nozzles for the European Space Agency’s (ESA) Ariane program by October 2025, reducing both costs and production timelines.
Innovations for Zero-Emission Hydrogen Engines
With the EU’s ReFuelEU Aviation Regulation mandating a 60% reduction in CO2 emissions by 2050, Fraunhofer ILT’s LPBF 3D printing capabilities align with the need for low-carbon aerospace solutions. Supported by the German Federal Ministry for Economic Affairs and Climate Action, the TRIKA initiative promotes hydrogen as a zero-emission aviation fuel. The Fraunhofer team has developed 3D printing powders that resist hydrogen embrittlement, achieving 99.5% relative density in printed components. This process supports complex geometries and high-strength parts for aerospace applications, facilitating the design of lightweight components that help reduce aircraft fuel consumption.
LCA Insights: Sustainability of 3D Printed Aerospace Parts
Fraunhofer ILT’s LCAs reveal that while LPBF 3D printing consumes substantial energy, it has a considerably lower environmental footprint than traditional methods due to minimized material waste and the ability to create lightweight, fuel-efficient parts. The LCA framework evaluates every stage of the component lifecycle, providing a transparent overview of quality, energy consumption, and resource usage.
Supporting ESA’s ENLIGHTEN Project for Green Rocket Technology
Fraunhofer ILT’s expertise also supports the ENLIGHTEN project, which aims to develop cost-effective, sustainable rocket engines powered by bio-methane and green hydrogen for the ESA’s Ariane program. The Additive Manufacturing and Repair LMD group at Fraunhofer ILT is advancing the production of thin-walled rocket nozzles with intricate cooling channels, streamlining a complex and expensive traditional production process. By integrating sensors into the LMD process, Fraunhofer ILT is building a quality-assured, reliable production method for large-scale, high-performance rocket parts.
Global Adoption of Additive Manufacturing in Aerospace
The aerospace sector’s adoption of additive manufacturing is rapidly expanding. SpaceX, for instance, has invested in Velo3D’s metal 3D printers to enhance production for its Raptor engines, emphasizing consolidation of parts and design optimization. Similarly, South Korea’s InssTek, in collaboration with the Korea Aerospace Research Institute (KARI), developed a multi-material 3-ton rocket nozzle using directed energy deposition (DED), essential for complex designs requiring robust, multi-alloy structures.
