AlForAMA · Project

3D-Printable High-Strength Aluminum Alloy for Lighter Aircraft Parts

manufacturingTestedTRL 5

Imagine you want to 3D-print airplane parts from aluminum, but the alloys available today crack too easily or corrode too fast when printed layer by layer. This team designed a brand-new aluminum recipe specifically built for laser-based 3D printing — think of it like inventing a flour blend that finally works in a bread machine instead of forcing regular flour to do the job. They optimized everything from the metal powder to the heat treatment, then proved it works by manufacturing 2 real aircraft demonstrator parts.

By the numbers

Demonstrator components manufactured

Consortium partners

Countries involved (Belgium, Spain)

Total project deliverables

The business problem

What needed solving

Aircraft manufacturers need lighter, stronger aluminum parts that can be 3D-printed — but today's commercially available aluminum alloys for additive manufacturing crack easily, corrode faster, and deliver weaker mechanical performance than what aerospace applications demand. Companies are stuck choosing between the design freedom of AM and the material performance of traditional manufacturing.

The solution

What was built

The project created a new high-strength aluminum alloy specifically designed for Selective Laser Melting, along with optimized processing parameters and heat treatments. They proved it works by manufacturing characterization specimens and 2 full demonstrator components for aircraft structural applications.

Audience

Who needs this

Aerospace Tier 1 suppliers printing structural aluminum componentsMetal 3D printing service bureaus serving aerospace clientsAluminum powder manufacturers looking for new AM-grade alloy formulationsDefense contractors lightweighting vehicle and aircraft structuresSpace industry manufacturers producing satellite structural parts

Business applications

Who can put this to work

Aerospace manufacturing

enterprise

Target: Aircraft structural component manufacturers and Tier 1 suppliers

If you are an aerospace parts manufacturer struggling with the limited selection of aluminum alloys available for additive manufacturing — this project developed a high-strength Al alloy specifically designed for Selective Laser Melting with improved weldability and corrosion resistance compared to cast-grade alloys. They validated it by manufacturing 2 demonstrator components, proving it can produce defect-free structural aircraft parts.

Additive manufacturing services

mid-size

Target: Metal 3D printing service bureaus and powder suppliers

If you are a metal AM service provider whose aerospace clients keep asking for stronger, more corrosion-resistant aluminum options — this project created a new alloy with tailored chemical composition and optimized SLM processing parameters. The powder can be produced via atomization or mixing of starting powders, giving you flexibility in your supply chain.

Defense and space

enterprise

Target: Defense contractors and satellite component manufacturers

If you are a defense or space company looking to reduce weight in structural components without sacrificing strength — this project demonstrated that their custom aluminum alloy delivers improved mechanical performance and corrosion resistance through laser powder bed fusion. The 2 manufactured demonstrators confirm the process works at component level for structural applications.

Frequently asked

Quick answers

What would it cost to adopt this alloy in our production?

The project data does not include specific cost figures. However, the alloy powder can be produced via standard atomization or by mixing existing powders, which suggests compatibility with current powder supply chains. Licensing or material costs would need to be discussed directly with the consortium.

Can this scale to industrial production volumes?

The project validated the alloy and SLM process at component level with 2 manufactured demonstrators. Scaling to series production would require further industrialization work, as the consortium was research-focused (2 research institutes and 1 university) with no industrial manufacturing partner.

What is the IP situation — can we license this alloy?

The project was funded under Clean Sky 2 (CS2-IA), which typically involves specific IP arrangements with the Clean Sky Joint Undertaking. The alloy composition and processing parameters are likely protectable IP held by the 3-partner consortium led by LORTEK. Licensing terms would need to be negotiated directly.

How does this compare to existing AM aluminum alloys like AlSi10Mg?

The project objective explicitly states this alloy offers improved weldability and increased mechanical and corrosion resistance compared to cast-grade aluminum alloys currently used in additive manufacturing. Specific performance numbers would be available in the project's characterization deliverables.

Is this alloy qualified for flight-critical parts?

The project demonstrated feasibility at component level with 2 demonstrators under the Clean Sky 2 aerospace program. Full aerospace qualification (e.g., EASA certification) would require additional testing and certification steps beyond the project scope.

What heat treatments are needed after printing?

The project developed a specific heat treatment optimized for the unique microstructural characteristics that SLM generates, rather than using conventional heat treatments designed for cast or wrought alloys. Details of the thermal treatment parameters would be available from the consortium.

Consortium

Who built it

The AlForAMA consortium is a compact, research-heavy team of 3 partners across 2 countries (Spain and Belgium). It includes 2 research organizations (LORTEK and IMDEA, both Spanish) and 1 university (KU Leuven, Belgium). Notably, there are zero industrial partners and zero SMEs — the entire consortium is academic and research-focused. For a business looking to adopt this technology, this means the science is strong but there is no built-in path to commercialization through an industry partner. You would be working directly with research institutes to transfer the technology into your production environment.

LORTEK S COOPCoordinator · ES
FUNDACION IMDEA MATERIALESparticipant · ES
KATHOLIEKE UNIVERSITEIT LEUVENparticipant · BE

How to reach the team

LORTEK S COOP is a technology center in Spain's Basque Country specializing in joining and manufacturing technologies. Contact their additive manufacturing department.

Order a report on this consortium See LORTEK S COOP profile →

Next steps

Talk to the team behind this work.

Want an introduction to the AlForAMA team to discuss licensing their aluminum alloy for your AM production? SciTransfer can arrange a direct meeting with the researchers.

Order a report on this topic More in Manufacturing & Industry 4.0