Select the Right Printing Technology for AeroDef: Using Post Processing to Help

3D printed parts in the aerospace and defense (AeroDef) sector often face challenges in achieving a high-quality surface finish. These challenges can arise from multiple factors, including the printing method, layer size and alignment, part orientation, and the material's particle size and behavior during the additive manufacturing process.
While the advantages of additive manufacturing (AM) are increasingly recognized—such as the ability to create complex geometries with intricate designs, lightweight structures, and optimized internal passages—the principle of trade-offs remains relevant. For instance, a metal printed part can exhibit significant variations in surface finish, even within the same component, which complicates the ability to meet stringent aerospace specifications.
This variability raises several critical questions: Can the surfaces of this part meet its functional requirements for performance and reliability? Does it need to be friction-free, or must it comply with specific fit, tolerance, or mechanical standards? How do the costs associated with 3D printed parts compare to those of traditional manufacturing methods, especially when considering expenses related to printing, post-processing, and finishing?
To assist stakeholders in the AeroDef industry, we provide insights using advanced aerospace and defense product examples, showcasing various metal post-processing techniques such as abrasive finishing, blasting, chemical finishing, and electropolishing. Each of these methods can enhance surface quality, reduce roughness, and improve overall performance.
We also delve into different additive manufacturing techniques and materials, discussing their pros and cons for specific applications in aerospace and defense. By evaluating these factors, we aim to equip industry professionals with the knowledge needed to make informed decisions about the best manufacturing processes and finishing techniques for their unique requirements, ultimately leading to enhanced performance and compliance in critical applications.