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Additive Manufacturing and Lightweight Materials for Aerospace and Defense 2018-2028

Technology assessments, player profiles and strategies, market forecasts

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The aerospace and defense sector is key to assess when it comes to the adoption of any emerging technology. The main players have specific material requirements and big budgets to address their needs. Analysing this sector gives vital insights into longer term trends, in many cases a trickle-down effect of these technologies will be seen into higher-volume and lower budget transportation industries over time.
One of the key demands is lightweighting. Aerospace has the highest carbon footprint per tonne-km over any other mode of transportation and regulatory demands and economic advantages mean that saving any weight is a constant target. Despite the increase regulatory pressure, the aerospace industry remains very healthy with a CAGR of 6.2% for aircraft deliveries from Boeing and Airbus since 2010 and significant number of backorders in place.
This report looks at the key lightweighting approaches for this sector and which players and technologies stand to be the main winners and losers, the predominant focus is on advanced lightweight materials and the rise of additive manufacturing. The material outlook is for all aerospace and defense applications, aircraft have the highest demand by volume and the applications investigated ranges to structural load-bearing roles, interiors, jet engines, and more.
This research was conducted through extensive research from IDTechEx. Granular 10-year market forecasts are provided for each section, and interview-based company profiles of innovative emerging companies addressing this sector are provided alongside this report.
Additive Manufacturing
Technology, Markets and Applications
In 2018, the 3D printing market comprises multiple different printer technologies. This report takes an in-depth look into established printer types compatible with polymer, metal and ceramic materials, including Vat Photopolymerisation (SLA/DLP/CLIP), Powder Bed Fusion (SLS/DMLS/EBM); Material Extrusion, Material Jetting, Binder Jetting and Directed Energy Deposition. Key technological capabilities, aerospace and defense manufacturing readiness levels, SWOT analyses and key manufacturers are discussed for each established printer type. In addition, compatible established material classes including Photosensitive Resins, Thermoplastic Powders, Thermoplastic Filaments, Metal Powders are presented and evaluated.
This report forecasts the key additive manufacturing technologies used by the aerospace and defense sector, with in depth discussion of currently commercialised and emerging printer technologies. The current state of the printer market is analysed, and long-range forecasts from 2018-2023 for accumulated and annual sales of printer technologies and materials including metal powders are evaluated.
Key AM questions that are answered in this report
  • What are the current and emerging printer technology types utilised in aerospace and defense?
  • What are the strengths and weaknesses of different additive manufacturing technologies?
  • Which printers support different material classes?
  • What are the additive manufacturing strategies of some of the market leaders?
  • What applications has additive manufacturing been employed in?
  • What are the key drivers and restraints of market growth?
Lightweight Materials
There are many types of materials that go into the composition of components in the aerospace and defense sector. This report tackles the key lightweight materials, of which the main candidates are outlined below.
This report targets those most relevant to the aerospace and defense sector including: composites (FRP, CMC, MMC), lightweight metals (Al, Ti, Mg), and other emerging materials (specifically polymer aerogels and CNT yarns).
For each material the reader will find:
  • Market forecasts
  • Critical technology assessment
  • Analysis of main players and supply chain
  • Profiles of emerging players
  • Initial and long-term applications
Analyst access from IDTechEx
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Table of Contents
1.1.Market drivers for lightweighting in the aerospace sector
1.2.Overview of the aerospace market
1.3.Material winners and losers in the aerospace and defense sector
1.4.Composite market forecast for aerospace and defense sector
1.5.Timeline for FRPs in the civil aerospace sector
1.6.lightweight metals market forecast for the aerospace and defense sector
1.7.Status of early stage lightweight materials and initial applications
1.8.Why adopt additive manufacturing?
1.9.Drivers and restraints of additive manufacturing
1.10.OEM AM strategy - GE
1.11.OEM AM strategy - Airbus
1.12.OEM AM strategy - Boeing
1.13.Additive manufacturing material market forecast for the aerospace and defense sector
2.1.FRP forecast for aerospace and defense sector
2.2.CMC forecast for aerospace and defense sector
2.3.CFRP applications - aircraft overview
2.4.CFRP applications - helicopter overview
2.5.Role of composites in jet engines
2.6.CFRP applications in next generation aircraft
3.1.Introduction to fiber reinforced polymers (FRPs)
3.2.Overview of FRP composition
3.3.CFRP players and supply chain
3.4.Innovations at each step of FRP manufacturing
3.5.Timeline for FRPs in the civil aerospace sector
3.6.CFRTP - a growing role in the aerospace sector
3.7.Phenolic resins and alternatives in aerospace interiors
3.8.Braided composites - applications and players
3.9.Prepreg material - next generation products
3.10.Spread tow fabrics for thin ply structures - overview
3.11.Spread tow fabrics for thin ply structures - aerospace applications
3.12.Natural fiber composites for aerospace interiors
3.13.S-Glass fibers
3.14.Boron fibers
3.15.Recycling composites - overview
3.16.Use of recycled composites in aerospace
3.17.Advancements in robotic automation for composites
3.18.Advancements in robotic automation for composites (2)
3.19.Robotic automation for thermoplastic composites
3.20.3D Printing of polymer composites - status and players
3.21.3D Printing of polymer composites - aerospace applications
3.22.Role of nanocarbon as additives to FRPs
3.23.Routes to incorporating nanocarbon material into composites
3.24.Metallized fiber for composites
3.25.Multifunctional polymer composites - overview
3.26.Key drivers for thermal and electrical property enhancements
3.27.Embedded sensors for structural health monitoring of composites - introduction
3.28.Embedded sensors for structural health monitoring of composites - types
3.29.Fiber optic sensors (FOS) for composite SHM
3.30.Embedded sensors for structural health monitoring of composites - methods
3.31.Embedded energy storage for multifunctional composites
3.32.Data transmission within composite parts
3.33.Routes to "self-healing" composite parts
4.1.Introduction to ceramic fibers
4.2.Manufacturing continuous SiC fibers
4.3.Manufacturing continuous alumina fibers
4.4.Introduction to ceramic fiber monofilaments
4.5.CMC - main players
4.6.SiC/SiC CMC applications - aerospace and defense
4.7.Ox/Ox CMC applications - aerospace and defense
5.1.Introduction to MMCs
5.2.Classification and relationship of metal matrix additives
5.3.Comparison of additives by type
5.4.Overview of key additive innovations
5.5.Continuous ceramic fiber MMC - applications
5.6.Chopped ceramic fibers MMC - applications
5.7.Ceramic particle MMC - applications
5.8.Aluminium MMC Forecast by additive type and form
5.9.Aluminium MMC Forecast by application
6.1.Aluminium Alloys
6.1.1.Aluminium introduction and properties
6.1.2.Overview of Aluminium-Lithium alloys
6.1.3.Li-Al forecast for aerospace and defense sector
6.1.4.Overview of Aluminium-Beryllium alloys
6.1.5.Market forecast for Be-Al alloys
6.1.6.Overview of aluminium-scandium alloys
6.1.7.Production outlook for scandium oxide forecast
6.1.8.Emerging role of Scalmalloy
6.2.Titanium Alloys
6.2.1.Titanium - overview and key properties
6.2.2.Titanium players for the aerospace and defense sector
6.2.3.Relationships between titanium players and aerospace OEMs
6.2.4.Titanium alloys forecast for aerospace and defense sector
6.2.5.Advancements in Titanium Alloys
6.2.6.Overview and outlook for titanium aluminide (TiAl)
6.2.7.Advancements in titanium processing
6.2.8.Application of titanium alloys in aerospace and defense
6.3.Magnesium Alloys
6.3.1.Introduction to magnesium and alloys
6.3.2.Advantages and disadvantages of magnesium
6.3.3.Main players in magnesium supply chain
6.3.4.Advancements in metal manufacturing
6.3.5.Main aerospace applications
6.3.6.Emerging application for aerospace interiors
6.3.7.Magnesium alloys forecast for aerospace and defense sector
7.1.What is an Aerogel?
7.2.Classification and relationship of aerogel types
7.3.Introduction to polymer aerogels
7.4.Polymer aerogels - Aerogel Technologies
7.5.Polymer aerogels - BASF and Blueshift International Materials
7.6.Polymer aerogels for aerospace interiors
7.7.Polymer aerogels for aerospace antennas
7.8.Research into polymer aerogels - NASA
8.1.Introduction to carbon nanotubes (CNT)
8.2.Introduction to CNT yarns
8.3.Formation and benchmarking of CNT yarns - main players
8.4.Post yarn modification and challenges
8.5.Role of CNT aspect ratio
8.6.CNT yarns - specific conductivity
8.7.CNT yarns - Ampacity
8.8.CNT yarns - temperature coefficient of resistance
8.9.CNT yarn aerospace and defense applications
8.10.Emerging CNT yarn applications
9.1.Why adopt additive manufacturing?
9.2.Major material-process relationships
9.3.Computer Aided Engineering (CAE): Topology
9.4.Drivers and restraints of growth
9.5.The different types of additive manufacturing processes
10.1.Powder bed fusion: Selective Laser Sintering (SLS)
10.2.Extrusion: Thermoplastics (TPE)
10.3.Vat photopolymerisation: Stereolithography (SLA)
10.4.Vat photopolymerisation: Digital Light Processing (DLP)
10.5.Material jetting
10.6.Binder jetting: polymer binder jetting
10.7.Photosensitive resins
10.8.Thermoplastic powders
10.9.Thermoplastic filaments
10.10.High temperature thermoplastic filaments and pellets
10.11.Composite thermoplastic filaments
11.1.Powder bed fusion: Direct Metal Laser Sintering (DMLS)
11.2.Powder bed fusion: Electron Beam Melting (EBM)
11.3.Directed energy deposition: Blown Powder
11.4.Directed energy deposition: Welding
11.5.Binder jetting: Metal Binder Jetting
11.6.Extrusion: Metal + polymer filament (MPFE)
11.7.Vat photopolymerisation: Digital Light Processing (DLP)
11.8.Material jetting: nanoparticle jetting (NJP)
11.9.Material jetting: magnetohydrodynamic deposition
11.10.Material jetting: microfluidic electroplating
11.11.Powder morphology requirements
11.12.Water or gas atomisation
11.13.Plasma atomisation
11.14.Powder morphology depends on atomisation process
11.15.Supported materials
11.16.Suppliers of metal powders for AM
11.17.Alloys and material properties
11.18.Aluminium and alloys
11.19.15-5PH stainless steel
11.20.Nickel superalloy: Inconel 718
11.21.Titanium and alloys
11.22.Metal powder bed fusion post processing
11.23.AM of High Entropy Alloys
12.4.GE Aviation: LEAP fuel nozzles
12.5.Boeing 787 Dreamliner: Ti-6Al-4V structures
12.6.Boeing: metal microlattice
12.7.Autodesk and Airbus: optimised partition wall
12.8.Airbus: bracket
12.9.RUAG Space and Altair: antenna mount
12.10.Hofmann: oxygen supply tube
13.1.Printer units supply forecast: installed base and annual sales
13.2.Material demand forecast by mass
14.1.3D Systems
14.2.Acellent Technologies
14.3.Aerogel Technologies
14.6.Advanced Powders and Coatings (AP&C)
14.7.Arcam AB
14.8.Argen Corp
14.9.Blueshift International Materials
14.13.Composite Horizons
14.14.Concept Laser
14.17.FRA Composites
14.18.Free Form Fibers
14.19.Gamma Alloys
14.22.Lockheed Martin
14.23.LPW Technology
14.29.Norsk Titanium
14.30.North Thin Ply Technology (NTPT)
14.37.SLM Solutions
14.38.Specialty Materials

Report Statistics

Slides 320
Companies 40
Forecasts to 2028

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