Advances in 3D printing enable faster production for aerospace and industry

3D printing is becoming increasingly important in the manufacturing industry, especially in aerospace, where precision and efficiency are critical. NASA‘s recent success, in collaboration with Protolabs, is an impressive demonstration of how generative design tools and advanced manufacturing technologies can accelerate the process from idea to finished prototype. This collaboration highlights the benefits of 3D printing and AI-powered design optimisation, which could be key in the future not only in the US, but also in the European aerospace industry.

“For a successful demonstration of our idea, it was crucial that the manufacturer we chose to produce the prototype delivered the part we ordered on time. Therefore, there was no margin for error or delay,” emphasised Matthew Vaerewyck, mechanical engineer at NASA’s Goddard Space Flight Center in Greenbelt, Maryland. “To successfully realise NASA’s project, we made a conscious decision to work with Protolabs because it is the only digital manufacturer in the world that combines a digital manufacturing process with speed and reliability while ensuring a high level of quality.”

As part of a presentation at the PowerSource Global Summit, NASA engineers presented a new approach for the rapid production of prototypes for the Artemis moon mission. The goal was to develop a device that collects gas samples on the moon. The design requirements – including modularity, stackability and interaction with robots – were defined using a NASA generative design tool. The resulting CAD model was then uploaded to Protolabs, who produced the prototype within a few hours using CNC machining.

“We are pleased to have been a manufacturing partner on this novel project that demonstrates the impact of combining generative design and automated manufacturing,” said Greg Thompson, Senior Director of CNC Machining at Protolabs. “As a company that has revolutionised manufacturing, Protolabs is proud to play a central role in this NASA mission, pushing the boundaries of innovation to enable space exploration.”

“Speed, quality and the ability to draw on external expertise in part design are essential for the aerospace industry,” explains Daniel Cohn, Managing Director of Protolabs Germany. “The example from the USA clearly shows that we have entered a new era in this area thanks to AI and Protolabs’ manufacturing expertise. However, while the joint project with NASA was limited to CNC manufacturing, we must emphasise the relevance of additive manufacturing for Europe at this point. This technology – combined with the know-how of Protolabs’ experts – can turn virtually any design created by AI into reality overnight.”