How Laser Manufacturing Transforms Aerospace Engineering

Laser Tech Revolutionizes Aerospace Engineering with Lighter, Faster Parts

The aerospace industry is turning to advanced laser technology to meet growing demands for efficiency and sustainability. Researchers at the Fraunhofer Institute for Laser Technology (ILT) are leading the way with innovative manufacturing methods. These techniques promise faster production, lighter components, and lower costs—key goals for both aviation and space exploration.

At the heart of this progress is Dr. Thomas Schopphoven, who heads the Laser Material Deposition (LMD) department at Fraunhofer ILT. His team is currently focused on producing structural aircraft parts using laser-based additive manufacturing. The technology allows for components with optimised shapes, reduced weight, and enhanced durability—critical for applications like rocket engines.

Two key methods, Laser Powder Bed Fusion (LPBF) and LMD, are transforming how high-performance parts are made and repaired. LPBF, for instance, now works with copper materials, enabling the creation of thin-walled, high-density structures with superior thermal management. This breakthrough is particularly valuable for aerospace, where heat resistance and weight savings are essential. The benefits extend beyond production. Additive manufacturing also simplifies maintenance, cutting supply chain delays and reducing operational costs. Fraunhofer ILT’s approach has already slashed development times, turning a CAD model into a working prototype in just days. These advancements come as private space companies like SpaceX, Blue Origin, and Rocket Lab push for faster, cheaper access to space. Meanwhile, climate pressures are driving the need for greener aviation solutions. Additive manufacturing supports this shift by minimising material waste and enabling lighter, more fuel-efficient aircraft designs.

The combination of laser technology and additive manufacturing is set to reshape aerospace engineering. Faster production cycles, stronger yet lighter components, and reduced environmental impact are now within reach. For industries facing tight budgets and sustainability targets, these innovations offer practical solutions for the future.