Aerospace manufacturers operate in one of the most demanding industrial environments. Weight reduction, thermal performance, material efficiency, and process repeatability are crucial for achieving reliable and cost-effective operations.
AltForm supports aerospace OEMs and Tier-1 suppliers with advanced laser technologies, including Powder Bed Fusion and Direct Energy Deposition, as well as automated coating and surface treatment systems specifically engineered for high-performance aerospace applications.
Our solutions are designed to combine lightweight design, mechanical strength, and consistent quality, enabling a new level of industrial efficiency across aircraft, propulsion systems, and space applications.
Lightweight, high-performance components with Powder Bed Fusion
AltForm’s Powder Bed Fusion (PBF) systems, including the Print 300 and Print 400 platforms, enable the production of complex aerospace components with optimized geometries and reproducible performance.
Typical aerospace applications include:
- lightweight lattice structures for airframe assemblies
- hydraulic and pneumatic components with integrated channels
- heat exchangers and thermal management parts
- brackets, supports, and structural elements with optimized strength-to-weight ratios
Combined with our AI-enabled human-machine interface, users gain real-time insight into process conditions, advanced monitoring capabilities, and predictive tools that help maintain quality in demanding production environments.
Large-scale structures and reactive materials with Direct Energy Deposition
For large and complex aerospace parts, AltForm provides Direct Energy Deposition (DED) solutions through the ZENIT multi-process robotic cell.
ZENIT integrates Powder DED, Wire DED, WAAM, and inert-gas processing in a single system, enabling the controlled deposition of reactive materials such as titanium and aluminum.
Use cases include:
- near-net-shape manufacturing of large titanium components
- repair and remanufacturing of structural aerospace parts
- production of high-strength aluminum components
- thick-walled structures and functional prototypes for aerospace R&D
Our inert-atmosphere solutions and advanced process monitoring ensure stable operation when working with materials that require precise environmental conditions. Our technology is based on an exclusive patent for the rapid and controlled inertization of the work chamber, which creates a stable environment in a short time and allows you to process highly reactive materials in conditions of safety and consistent quality.
Materials and processes for aerospace standards
AltForm supports high-performance materials essential for aerospace applications, including titanium alloys, copper alloys, advanced aluminum grades, superalloys, and specialty steels. These materials enable the production of lightweight, heat-resistant, and durable components designed to meet the strict mechanical and environmental requirements of flight-critical systems. Through precise process control, integrated automation, and intelligent interfaces, we ensure stability, full traceability, and consistent quality even at industrial production scale.
In aerospace, compliance with rigorous standards is fundamental. The NADCAP (National Aerospace and Defense Contractors Accreditation Program) certification is one of the most demanding frameworks in the sector. AltForm supports customers throughout the entire qualification journey, from process verification to powder validation and testing on finished components. This enables manufacturers to achieve a standardized, repeatable, and fully qualified additive manufacturing workflow for aerospace parts.
Digital passport and blockchain-based part protection
AltForm’s software suite integrates advanced tools for production control, process management, and data protection. Each component can be equipped with a blockchain-based digital passport, which certifies:
- complete process traceability
- production parameters
- quality and monitoring data
- environmental conditions recorded during the process
Additionally, the component design can be protected via blockchain, ensuring secure file management, prevention of unauthorized copying, and secure storage of intellectual property. This is particularly important for critical or classified components, such as those used in defense and space.
Industrial innovation that creates real value
Our approach to innovation is straightforward: we solve real industrial challenges with reliable and scalable laser-based manufacturing solutions.
By combining advanced additive technologies, automation, and AI-enabled control systems, we help aerospace manufacturers produce lighter components while maintaining high mechanical performance and consistent quality.
This approach supports operational efficiency, reduces overall production costs, and contributes to lower environmental impact. Above all, it enables manufacturers to scale their production processes with confidence and long-term stability.
Our solutions for the aerospace industry
Print 300 Series
Print 400 Series
ZENIT Cell
