JANUARY 19, 2023

Additive Manufacturing and New Space

By Daniel Keyser

Keywords
Additive Manufacturing, New Space, Low Earth Orbit, Rockets, Launch
Package, Satellites, Combustion Chambers

Overview
The New Space Race, or simply New Space as it is commonly referred to, is
a rapidly expanding industry covering several industrial manufacturing
fields focused at utilizing the recently rediscovered arena of space to advance
business interests. New Space is seeing interest from
One of the notable changes in aerospace companies seeking to put communications, observa-
design has been an acceptance of tion, lab packages, test beds and potentially mining
additive manufacturing into both the into space, and is showing no signs of slowing down.
manufacturing and design process. Driving this billion-dollar industry are a wide array
of businesses and visionaries looking to reach out
and grow this burgeoning industry with the potential to change the course
of humanity.

Additive Manufacturing Advantages in Aerospace

Traditional aerospace frames have seen a revolution in the last thirty years.
Designs have been pushed to maximize flight and weight characteristics us-
ing new designs and materials. This can mean anything from increased
efficiency for turbofan assemblies inside of jet engines to new bracing struc-
tures running along aircraft wings to reduce weight and increase fuel
efficiency. One of the notable changes in aerospace design has been an ac-
ceptance of additive manufacturing into both the manufacturing and design
process. Modern engines have complex geometries that are perfect for addi-
tive manufacturing, as these engines are developed and revised to increase
power, performance, or efficiency for a more sustainable future. 3D printed
parts incorporating technologies like Design for Additive Manufacturing
(DfAM) and Generative Design allow engineers to push for more out of their
production parts. Designers see increased adoption of additively

VISION, EXPERIENCE, ANSWERS FOR INDUSTRY

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manufactured parts for both internal and external components. These parts
are not just limited to standard civilian airliners either, they also see adoption
in drones, military aircraft, helicopters, sea-based planes and spacecraft and
satellites for extraterrestrial activity. Repeatedly, additively manufactured
parts prove to be an efficient, reliable, and in some cases, better part than can
be created through traditional manufacturing options. Additively manufac-
tured parts still must undergo a strict process to be certified for use, and any
changes in the design of parts for airframes or their composition must meet
a strict requirement for certification. However, the ability to further lighten
aerospace parts while maintaining or improving on the stiffness of the part
has led to many manufacturers looking to adopt these designs into their air-
frames if they haven’t already.

This comes down to three main advantages in additive. First, material choice
allows for end users to print a variety of parts, either polymer or metals, in
several different ways. Aerospace for external parts usually relies on metal
blends, but these blends can be tweaked to achieve better results based on
the characteristics of the part. Second, the design process of additive manu-
facturing, including the printing of the part, can be tweaked to allow new
structures and supports the internal design that would be either impossible
or expensive to mill. Finally, the additively manufactured parts can be more
efficient in their design and construction, allowing multiple components to be
integrated into one part.

The Growing New Space Race

New Space, sometimes called Alt.Space and other times known as the com-
mercialization of space, is a growing industrial field tapping into experts in
metallurgy, electronics, aerospace, traditional space industries, govern-
ments, as well as a growing interest from mining concerns. Companies are
investing in potential and technological advances while assessing the viabil-
ity of some space operations. Primarily, New Space has been focusing
towards launching satellites, mainly communications networks, and orbital
space flight, both of which it has proven in the last few years, with NASA
even utilizing commercial launch vehicles for its missions. New Space is also
attracting attention towards orbital tourism and has pipeline dreams to-
wards mining of asteroids, which could bring in untapped billions in
minerals.

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The list of companies pursuing New Space is ever expanding - from a NASA
document on the commercialization of space in 2015, 19 companies were
identified and listed as examples. That list of examples has grown exponen-
tially as new companies jump on board to reach the stars and break into the
market. Morgan Stanley estimated in 2016 that the market of $350 billion was
on track to reach the trillions by 2040. In 2021 alone,
Additive manufacturing’s unique ability to New Space enterprises reached $469 billion.
print organically inspired architecture in
structures while consolidating multiple parts
into one piece allow New Space companies Additive Manufacturing and New Space:
to build products faster and more reliably A Winning Combination
than standard subtractive methods.
New Space is growing rapidly, and additive man-
ufacturing is uniquely positioned to help benefit it.
Building upon the vast body of work already being done in traditional aero-
space, the New Space industry has already found additive manufacturing to
be of use in their projects. Additive manufacturing occupies a key space for
manufacture, in that it meets a sweet spot between complexity of design,
consolidation of parts, materials advantage, while also uniquely keyed to the
production series size required for space flight and outperforming costs of
traditional manufacturing options.

Additive manufacturing’s unique ability to print organically inspired archi-

tecture in structures while consolidating multiple parts into one piece allow
New Space companies to build products faster and more reliably than stand-
ard subtractive methods. New Space continues to help drive additive as well;
consider recent trade shows at IMTS and Formnext, how many combustion
chambers with integrated cooling systems, how many bell nozzles, how
many fuel containment chambers were on display as a show of prowess
within the additive manufacturing space?

Recommendations
New Space is a huge opportunity for several industries, and it shows an up-
ward trend year after year as it steadily climbs. The main hindrance to further
adoption to additive manufacturing within the New Space industry seems to
be related to viable materials for some applications or to the high cost per
part against traditional manufacturing methods. The vast array of companies
already involved in New Space have already begun to utilize additive print-
ers to help them achieve their goals. The market is set to continue growing,
and as it does, additive manufacturing and New Space will continue to grow

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hand and hand as companies seek to develop new initiatives and products
that only additive manufacturing can fill. Per Aspera ad Astra – a Latin phrase
that means through hardships to the stars.

Based on ARC research and analysis, we recommend the following actions

for owner-operators and other technology users:

• The Certification process for aerospace parts is rigorous, with updates in

designs or materials having to undergo full retesting for the part, under-
stand this cost to time and initial prices before entering additive for New
Space applications.

• Additively manufactured parts are potentially more expensive on a price

per part basis, but the enhanced quality of the parts, the consolidation of
many different parts into one, and the design aspect advantages that ad-
ditive has allow the parts to perform better than traditionally
manufactured parts.

• Explore the New Space industry to find applications and business in

helping to print parts for launches. Similarly, explore the additive man-
ufacturing industry to assess your needs for your specific launch
missions and how additive can help reduce expense or create better qual-
ity parts if you have not done so.

For further information or to provide feedback on this Insight, please contact your
account manager or the author at DKeyser@arcweb.com. ARC Insights are pub-
lished and copyrighted by ARC Advisory Group. The information is proprietary to
ARC and no part may be reproduced without prior permission from ARC.

©2023 • ARC • 3 Allied Drive • Dedham, MA 02026 USA • 781-471-1000 • arcweb.com