Discover AM Solutions for Aerospace & Defense at Formnext 2025

See how we are delivering mission-critical components with unmatched quality - gain insights into our workflows, discuss your application case with our experts, and see premier additive manufacturing parts.

Boost Electric Vehicle Performance Range with Lightweight, Highly Efficient Components

self flying passenger drone

The pivot towards green energy has resulted in greater adoption of eVTOLs, “flying cars,” electric helicopters, electric aircraft, and drones. Advances in the aerospace and defense industry are driving this adoption as well. All the new electric flying vehicles require highly efficient and lightweight electric motors to achieve reproducible high-performance take-off weight and flying range capabilities.

With additive manufacturing, you gain innovative design flexibility to create the lightweight, highly efficient electric motor parts (e.g., stators, rotors, heat exchangers, etc.) that enable these capabilities.

Streamline the Design and Production of Electric Engine Parts

  • interior curvature of cooling jacket

  • Achieve Integral Design

    Consolidate traditionally complex assemblies into a single 3D-printed design. Direct metal printing (DMP) gives you the significant design flexibility to combine different functional parts, allowing you to integrate thermal management geometries directly into your electric stator design and greatly reduce the complexities of conventional cooling features (e.g., heat exchangers).
  • prox dmp 320 cooling mantle

  • Lower Weight with Enhanced Functionality

    Use DMP to manufacture strong, lightweight electric motor components that maintain or enhance functional performance. Advanced DfAM can open new horizons for induction & heat transfer optimization. Since components made with DMP are lightweight, electric flying vehicles can carry more passengers or cargo without increasing costs.

More Aerospace and Defense Applications

Investment Casting
Metal 3D Printed DLR Fuel Injector

Propulsion
Thales Bracket Close-Up Aerospace

Lightweight Brackets
Laserform Heat Exchanger Closeup for Aerospace

Heat Exchangers

3D Printed Waveguides, Filters, and Antennas
  • imts spark logo

  • Flying into the Future with Joby Aviation

    Watch this webinar featuring Joby Aviation and learn how metal additive manufacturing fuels aerospace innovation.

Learn More About Our Solutions for Electric Engine Components Applications

LaserForm Ti Gr5 (A)

High strength, low weight, excellent biocompatibility

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3DXpert

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  • Application Innovation Group

    Our team can help you solve your most difficult design and production challenges with additive manufacturing solutions. Together we’ll identify your needs, working with you to optimize your designs, prototype, validate and define a manufacturing flow.
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