Jul 01, 2026
Safety-critical additively manufactured components for the aviation industry
TU Dresden’s DA62 research aircraft as well as key project areas focused on researching an innovative, additively manufactured fuel tank mount, with a demonstration on the research aircraft
The Institute of Lightweight Engineering and Polymer Technology (ILK) at TU Dresden is researching, within the project “Approved 3D-printed safety-related structural components for future aircraft” (3D4Lu), together with the Institute of Aerospace Engineering (ILR) at TU Dresden, certified 3D-printed safety-relevant structural components for future aircraft.
Motivation
Additive manufacturing (AM) processes such as laser powder bed fusion (LPBF) enable the flexible and resource-efficient production of structurally demanding metal components. Particularly in the aviation industry, which faces technological challenges due to increasing air traffic and the need for low-emission propulsion technologies, AM opens up new possibilities – especially for the development of new aircraft classes (General Aviation, UAVs, eVTOLs) as well as for retrofits of existing systems. However, the potential of AM is offset by uncertainties in predicting mechanical properties, which in practice often lead to conservative, one-size-fits-all post-processing and testing cycles. To fully exploit the efficiency benefits, technology-specific requirements must be holistically integrated across all phases – from initial design to final certification.
DfAM – Design for Additive Manufacturing
To ensure targeted post-processing and appropriate quality assurance measures, a design process is being developed that addresses the AM-specific characteristics of the material and process. Examples for DfAM elements include topology optimization, the reproduction of AM-typical imperfections for virtual validation, as well as surface and heat treatments. The practical application of this DfAM approach will be demonstrated in 3D4Lu using the example of a mounting bracket for a hydrogen pressure tank.
Certification and approval of AM Components
A structured certification process is required to demonstrate the airworthiness of the fuel tank mount in the research aircraft (DA62 MPP). The additive-manufactured fuel tank mount is used to validate the necessary certification steps, which can serve as a basis for follow-up projects and retrofits on the research aircraft.
Presentation of a prototype of the additively manufactured fuel tank mount as an interim result of the project at the “AERO Friedrichshafen” trade show in 2026.
Project Data
09/2025–12/2027
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Institute of Aerospace Engineering (ILR) at TU Dresden
This project is funded under the EFRE/JTF Research InfraProNet 2021–2027 programme by the Sächsische Aufbaubank (SAB), the Development Bank of the Free State of Saxony.
© ILK/TUD
Dr.-Ing. Sebastian Spitzer
Head of Lightweight design
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Institute of Lightweight Engineering and Polymer Technology
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Dipl.-Ing. Julian Barth
Research Associate
TUD Dresden University of Technology
Institute of Lightweight Engineering and Polymer Technology (ILK)
Holbeinstr. 3
01307 Dresden
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