Additive technologies: research, application in the design and manufacturing of aviation industry structural elements

Oleksandr Marynoshenko, Oleksii Chornyi

Abstract


The article focuses on the application of additive technologies in the design and manufacturing of aviation structural elements under modern requirements for strength, weight reduction, reliability, and economic efficiency. The goal of the study is to develop and substantiate an integrated analytical approach to optimizing additive manufacturing processes in aircraft production. The tasks addressed include: analyzing of current additive technologies in aerospace engineering; developing mathematical models of thermomechanical processes and porosity formation; optimizing of printing parameters and material composition; and conducting a comparative evaluation of traditional and additive manufacturing methods. The methods employed comprise the finite element method, thermomechanical and porosity modeling, multi-criteria optimization, and experimental investigation of the mechanical properties of metallic and polymer materials. The following results were obtained: mathematical models for predicting thermal deformation, structural heterogeneity, and strength characteristics were developed; the influence of process parameters on microstructure formation and defect minimization was determined; it was established that the optimization of printing parameters reduces material consumption by up to 30%, decreases product weight by 10–25%, reduces production time by a factor of 2–3, and lowers costs by up to 40%. A tensile strength of up to 1260 MPa was achieved for SLM-manufactured titanium components. In addition, the proposed integrated modeling approach enabled quantitative prediction of porosity levels and residual stress distribution, improving dimensional accuracy and structural reliability of critical aviation components. Comparative analysis confirmed that additive technologies demonstrate the highest efficiency in manufacturing geometrically complex and weight-critical parts, where traditional methods are limited in design flexibility and material utilization efficiency. Conclusions. The scientific novelty lies in the development of an integrated modeling and optimization framework for the additive manufacturing of aviation components, ensuring improved structural integrity, reduced defect levels, enhanced production efficiency, and increased competitiveness in aviation manufacturing.

Keywords


: finite element method; porosity analysis; optimization methods; printing parameters; experimental methods; mechanical strength; structural integrity; part quality

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References


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DOI: https://doi.org/10.32620/aktt.2026.2.05