Methodology for optimizing parameters and processes of metal component production for aerospace structures via additive manufacturing technologies

Oleksandr Dzhurynskyi, Sergey Filipkovskij

Abstract


This article provides an overview of current approaches to optimizing parameters and processes in additive manufacturing for aerospace metal components. The use of 3D printing technologies such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM) is considered, which enable the creation of parts with complex geometries, reduced mass, and improved operational characteristics. The importance of accurately selecting technological parameters is emphasized, as they directly affect the mechanical properties, durability, and reliability of the produced parts. Special attention is given to issues arising during additive manufacturing, such as material porosity, residual stresses, structural inhomogeneity, and insufficient dimensional accuracy. Methods for their elimination are analyzed, including numerical modeling of thermal processes, topology optimization of structures, and the application of machine learning algorithms for automated print parameter selection. The importance of integrating a comprehensive approach that combines experimental research with digital technologies is emphasized, as it significantly enhances product quality. The article focuses on the future development of additive technologies in the aerospace industry. Specifically, the possibilities of integrating artificial intelligence (AI) into print process management are explored, enabling not only quality control automation but also the prediction of potential defects at early stages of production. Additionally, the development of new metal alloys specifically tailored for 3D printing methods and the standardization of additive parts certification processes are discussed, as these are key factors for the widespread adoption of these technologies in aerospace manufacturing. Thus, the article summarizes the latest research in the field, identifies key problems, and outlines potential solutions. The comprehensive analysis and implementation of modern additive manufacturing optimization methods will improve efficiency, reliability, and cost-effectiveness in aerospace 3D printing applications.

Keywords


Additive technologies; 3D metal printing; aerospace structures; parameter optimization; topology optimization; artificial intelligence; quality control

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References


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DOI: https://doi.org/10.32620/oikit.2025.106.02

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