ATI and MTC Launch 2028 Roadmap to Revolutionize Additive Manufacturing in Aerospace [/download link]

The Aerospace Technology Institute (ATI), supported by the Manufacturing Technology Centre (MTC)—the National Centre for Additive Manufacturing—has unveiled a comprehensive strategy and roadmap for additive manufacturing (AM). This new plan envisions a transformative leap in AM technology by 2030, aiming for a substantial increase in the number of flying AM parts used in civil aerospace. This goal is to be achieved through a fully capable, end-to-end UK supply chain.

To realize this vision, it is essential to align technology development with critical product decisions anticipated by industry stakeholders in the 2028 timeframe, as they prepare for next-generation commercial aircraft.

The roadmap highlights: “The UK has all the essential elements for large-scale aerospace AM production, including a robust AM network with machine OEMs, a rapidly expanding supply chain, and unmatched academic expertise.”

The roadmap emphasizes the need for a unified effort to shift the focus from research and development to the production of end-use parts. Additive manufacturing is expected to play a crucial role in supporting aviation’s Net Zero 2050 goals and enhancing the global competitiveness of the UK aerospace sector.

Alex Hickson, Head of Technology – Structures, Manufacturing & Materials at ATI and co-author of the roadmap, stated: “Advancing our capabilities and integrating additive manufactured parts into aircraft are vital steps toward achieving Destination Zero. This roadmap outlines the strategic direction and key milestones necessary for boosting UK competitiveness and capitalizing on the economic opportunities in this field.”

Katy Milne, Future Mobility Associate Director at MTC, added: “The aerospace sector is experiencing unprecedented innovation, with new, more sustainable aircraft and more integrated supply chains being developed. AM is a critical enabler in this evolution.

“By sharing insights through this roadmap, OEMs and Tier 1 suppliers will be better equipped to make informed decisions on optimizing AM for next-generation aircraft. This will help supply chains build the necessary capabilities to meet future demands and ensure a prosperous future for UK aerospace manufacturing.”

Additive manufacturing has the potential to deliver products with improved fuel efficiency, enhanced thermal management, and reduced mass. By consolidating complex assemblies into single parts, AM can significantly cut manufacturing costs, reduce waste, and simplify assembly. It also accelerates the time to market for complex, high-value products by lowering development costs and shortening development cycles.

While aerospace products from major players such as Airbus, Boeing, GE Aerospace, General Atomics Aeronautical Systems Inc., and Rolls-Royce are already benefiting from AM in UK facilities, there is still considerable untapped potential. To stay globally competitive, the UK must accelerate its adoption of AM technologies.

The roadmap focuses on four key challenge areas: strengthening supply chain resilience, improving qualification efficiency, reducing part costs, and expanding application opportunities. Addressing these challenges will build confidence in AM, enabling decision-makers to integrate this technology into future programs confidently.

Developed with input from over 50 partners across the aerospace supply chain, including OEMs, the ATI AM Strategy and Roadmap includes case studies from Airbus, Eaton, GKN Aerospace, and Rolls-Royce, showcasing the benefits of AM in parts production, thermal management, and maintenance, repair, and overhaul (MRO).

The ATI Additive Manufacturing Strategy and Roadmap is now available for download here:

“Additive-Manufacturing-Strategy-Roadmap-Sept-2024-Final.pdf”

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