Component Consolidation Through Metal 3D Printing
Several individual parts were combined into a single, functionally integrated component.
By consolidating multiple components into a single metal part, assembly effort, production time, and potential sources of error were significantly reduced.
✓ Fewer individual parts
✓ Less assembly effort
✓ Shorter development times
✓ Greater functional integration
✓ Greater design freedom
Project at a Glance
| Feature | Value |
| Material | Inconel 718 |
| Process | Metal 3D printing (LPBF/SLM) |
| Industry | Aerospace |
| Print time | 11 hours |
| Post-processing | Stress-relief annealing, sandblasting |
| Application | High-temperature-resistant combustion chamber component for rocket engines, designed for controlled combustion and the guidance of hot gases. Metal 3D printing enables complex geometries, a reduced number of components, and efficient manufacturing of high-stress aerospace components. |
🛠️ The Challenge
The combustion chamber liner combined numerous functions in a complex geometry. Using conventional manufacturing methods, this would have resulted in:
- many individual components
- numerous welds and joints
- significant assembly effort
- long production times.
The more complex a component becomes, the faster traditional manufacturing processes reach their limits.
💡 The Solution
➜ Using metal 3D printing, the entire geometry was manufactured as a single component.
➜ This allowed internal structures, cooling channels, and functional areas to be integrated directly into the design without additional assemblies or post-fabrication assembly.
➜ The result is a highly integrated component made of Inconel 718, which was specifically developed for demanding high-temperature applications.
🎯 The result
✓ Number of components reduced
Several components were combined into a single functional unit.
✓ Assembly effort minimized
The number of connection points, screws, and potential sources of error has been reduced.
✓ Greater reliability
Fewer individual parts mean a lower risk of failure.
✓ Faster development
Design changes can be implemented directly without tools.
✓ Shorter lead times
From CAD model to finished part in just a few days.
✓ Greater design freedom
Geometries that would be virtually impossible to achieve using conventional methods become possible.
Do you also have components made up of many individual parts?
If your component is bolted, welded, or assembled from multiple components, component consolidation can offer economic benefits.
Typical applications:
✓ Cooling channels and heat exchangers
✓ Fixtures and mounts
✓ Fluid and pneumatic components
✓ Mechanical assemblies
✓ Aerospace components
✓ Custom machine building
3D printing often offers the greatest potential for cost savings precisely where assembly costs arise.
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Onur Yildirim
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