Why Is DLS 3D Printing Technology Ideal for Aerospace? 

Protolabs has been making a name for itself in the manufacturing industry for many years. The company has not only mastered traditional production processes such as injection molding, but is also an expert in additive manufacturing, using a wide range of processes. From metals to polymers, it supports customers in a wide range of sectors, including aerospace, a key market for 3D technologies. While prototyping was one of the main applications for the latter, it has to be said that more and more end-use parts are being 3D printed. And Protolabs is an expert in this type of application, notably with Carbon’s resin process, Digital Light Synthesis (DLS). You might think that resin technology wouldn’t be the best option for aerospace, but the company proves differently. To find out why, we spoke to Dr. Philipp Amend, Director Operations PZB & Director Engineering 3DP. 

3DN: Could you briefly introduce yourself and Protolabs?

Hello, my name is Philipp Amend and I am responsible for 3D printing production at the Protolabs site in Putzbrunn (PZB), Germany. We support our customers in their manufacturing projects, and together we choose the right production method, be it 3D printing, CNC machining or Injection Molding.   This enables us to offer the best solution for every phase of the product life cycle in a customer and product-oriented manner. Among our manufacturing capabilities, we are equipped with Carbon solutions, including a large-scale Carbon L1 3D printer that enables us to print a large number of small parts, as well as larger ones – up to 300 mm.  

While Carbon’s DLS technology has often been used for elastomer materials, we are now able to print rigid parts from small to large for production, which is unique on the market. This is of particular interest to the aerospace industry. 

3DN: Why is Carbon’s DLS process suited to the aerospace market?

Carbon’s technology has several advantages for this sector. Firstly, it offers high resolution, design flexibility and the ability to design fully-dense parts with an excellent surface finish.  

Aerospace applications require high-performance resins. And it is precisely these materials that Carbon offers, tested and validated for production with all the necessary certification and documentation.  Compared with stereolithography, this is a considerable advantage: In SLA, there is almost no such documentation for production applications in regulated industries. What’s more, the resins on offer do not offer good UV stability and durability. 

3DN: Could you give us some application examples?

We have two interesting examples of parts printed on Carbon machines. The first is a Flow Distribution Unit that is used for fluid and airflow management. Here, Carbon’s technology has made it possible to design circuits to efficiently convey these fluids, as well as optimized, lightweight cooling channels. The resulting part is fully gas and liquid dense, it is hydrogen flow approved and the weight has been reduced. Printed with Carbon’s EPX 82 resin, the part boasts high strength and rigidity (tensile strength approx. 82 MPa) and excellent heat resistance (125°C at 0.45 MPa). 

The second example is a battery holder that stores and cools battery components. Little waste was generated as there was a high material yield (75%). 

More generally, we are able to design ducts and drones with lighter, higher-performance parts, as well as satellite components that are extremely heat-resistant and more durable. We can also 3D print structural prototypes to develop new aerospace designs more rapidly. 

3DN: How do you see the impact of Carbon’s DLS process on the aerospace industry’s overall manufacturing strategy and supply chain?

I can see several considerable impacts of the DLS process on the aerospace industry: 

• Firstly, the DLS process enables rapid prototyping and on-demand production, all without the need for tooling. It allows multiple design iterations as they are easy to handle.   

• It reduces manufacturing lead times from several weeks or months to just a few days. Manufacturers gain in flexibility and can adapt their production efficiently. 

• The technology reduces costs in a number of ways: waste reduction, lightweighting opportunities via lattice structures or internal channels, and so on. 

• We can integrate multiple functions into a single part. The ability to create complex, consolidated designs reduces the need for multiple components, lowering assembly costs and improving reliability. 

• Last but not least, consistent print quality makes it possible to envisage both small-scale and large-scale production. 

3DN: Why choose Protolabs to design parts for the aerospace industry?

One of the key factors contributing to the success of a project is proactive collaboration with our customers. We need to gather all requirements, manage expectations and find the best possible solution for the customer. 

We have a dedicated Customer Production Success (CPS) team that supports our customer throughout the product life cycle and finds the best possible solution. At Protolabs, we specifically optimize designs for the DLS process in terms of performance, cost and manufacturability. 

3DN: Any last words for our readers?

We work closely with Carbon. This collaboration is essential to keep us at the forefront of materials and process development. Our expertise in 3D printing enables us to push back the boundaries from prototyping to production.  Contact us to find out more! 

What do you think of the use of Carbon’s DLS technology for the aerospace sector?  Let us know in a comment below or on our LinkedIn, Facebook, and Twitter pages! Don’t forget to sign up for our free weekly Newsletter here, the latest 3D printing news straight to your inbox! You can also find all our videos on our YouTube channel. For more 3D printing news in the aerospace and defense sectors, check out our dedicated page HERE.

*Photo Credits: Carbon