INSIDER

Manufacturing & Prototyping

Portsmouth Naval Shipyard Welds First Ever Metal 3D-Printed Submarine Component

Engineers recently completed inspection, testing, and shipboard installation of a welded, additively manufactured (AM) copper‑nickel flange for the USS...

INSIDER

Materials

Researchers Introduce New Digital Calibration Method for 'Born Qualified' Parts

The Johns Hopkins Applied Physics Laboratory (APL) in Laurel, Maryland, is developing a comprehensive suite of capabilities to ensure that additively...

INSIDER

Materials

Army Advances Additive Manufacturing From Experimental Tech to Enterprise Sustainment Tool

The U.S. Army’s adoption of additive manufacturing took another major step forward in March with the opening of a new “Additive Makerspace” at...

INSIDER

Manufacturing & Prototyping

Developing a Digital Twin to Model Fatigue in 3D-Printed Spacecraft Parts

The rapid production of custom components for rockets and satellites is often essential to support design modifications, repairs, and operational needs in space travel....

INSIDER

Materials

Gore Challenges Wet Sealing with Dry Sealant for Permanent Aircraft Structures

For decades, wet sealing has been accepted as a necessary constraint in aerostructure manufacturing, despite its impact on throughput, variability and necessary...

INSIDER

Manufacturing & Prototyping

European Researchers Develop Self-Healing Composite Material for Spacecraft

Healable spacecraft structures could soon be possible thanks to cutting-edge composite technology. Swiss companies CompPair and CSEM, and Belgian company...

INSIDER

Materials

How Biomanufacturing Could Transform Defense Material Production

Biomanufacturing uses biological materials to create new materials. For example, bioengineered spider silk is lighter than carbon fiber and stronger than Kevlar — making it...

INSIDER

Manned Systems

Argonne AI Tools Power Safer, Faster Aerospace Inspections

Artificial intelligence (AI) is helping industry move faster, safer and smarter. A research collaboration among Spirit AeroSystems Inc., the U.S. Department of Energy’s (DOE’s)...

INSIDER

Design

Breakthroughs in Testing Solid-Fuel Ramjets Advance Research

Scientists at the U.S. Naval Research Laboratory are developing the next generation of solid-fuel ramjet (SFRJ) propulsion, addressing one of the field’s most persistent...

Articles

Mechanical & Fluid Systems

Aerospace Aluminum Laser Welding: Advancing Material Performance for the Future of Flight

Together, microsecond pulsing, alloy-specific pulse shaping, core-and-ring beam modulation, and controlled oscillation provide far greater precision than CW welding. Read on to learn how.

Articles

Manufacturing & Prototyping

Plasma Surface Activation for Stronger, More Durable CFRP Bonds in Aerospace

Achieving reliable adhesive bonds on CFRP surfaces remains a persistent engineering challenge. Plasma surface treatment has emerged as a pivotal solution, offering a fast, controllable, and non-destructive way to increase surface energy, improve wettability, and enhance adhesion across complex geometries. Read on to learn more.

Briefs

Materials

Next Generation Carbon Fiber Composites 3D Printer for Hypersonic Research

In collaboration with Auburn University’s Center for Polymers and Advanced Composites and the Department of Aerospace Engineering, the institute recently acquired a CF3D Enterprise Cell — a next-generation 3D carbon fiber composites printer set to define the future of the nation’s hypersonic programs. Read on to learn more.

INSIDER

Manufacturing & Prototyping

Meeting the Demands of Defense Production and Sustainment Through Additive Manufacturing

When a chilled water pump failed aboard a U.S. guided missile destroyer, maintainers ran into an all-too-familiar problem. The six-blade cooling rotor...

INSIDER

Design

How Airbus is Using w-DED to 3D Print Larger Titanium Airplane Parts

Airbus is using wire‑directed energy deposition (w‑DED) to 3D print titanium aircraft parts at much larger scales than earlier additive manufacturing methods allowed....

INSIDER

Materials

Can This Self-Healing Composite Make Airplane and Spacecraft Components Last for Centuries?

Researchers have created a self-healing composite that is tougher than materials currently used in aircraft wings, turbine blades and other...

INSIDER

Aerospace

European Researchers Leverage AI in Manufacturing Rocket Parts

Artificial Intelligence (AI), promises many benefits in all domains, and rocketry is no different. The European Space Agency’s Future Launchers Preparatory Program(FLPP) is...

INSIDER

Design

The Critical Impact Of SAE Aerospace Standards: Certified AS1895/7 and /23 Metal Seals

In an industry where failure is not an option and precision is paramount, aerospace manufacturers and suppliers are constantly seeking components and...

INSIDER

Defense

New 3D-Printable Nanocomposite Prevents Overheating in Military Electronics

U.S. Army and university researchers collaborated to develop a 3D-printable material using tiny particles that conduct heat and can be used to more efficiently cool...

Articles

Manufacturing & Prototyping

SAE Books: 'Automated Fiber Placement' with Ramy Hari

Ramy Harik, a Fulbright alumnus and director of the Clemson Composites Center, is pushing the boundaries of manufacturing with his latest book, Automated Fiber Placement: Status,...

Articles

Materials

How Lightweight Coatings Protect Aerospace and Defense Electronics

While stresses such as altitude changes, vacuum, vibration, moisture and chemical exposure have the potential to wreak havoc on electronic components, conformal coatings have become essential to providing protection in the midst of these challenges. Read on to learn more.

Articles

Mechanical & Fluid Systems

High-Flying Output: Key Machining Techniques for Structural Aircraft Components

Structural aircraft components and the methods for making them have changed significantly, driven by advancements in technology and new demands in the industry. Aerospace assemblies are becoming lighter and more complex, while every aspect of how these components are designed and made is evolving. Read on to learn more.

Briefs

Green Design & Manufacturing

Novel Chromium–Molybdenum Metal Alloy Withstands Extreme Conditions

A new material might contribute to a reduction of the fossil fuels consumed by aircraft engines and gas turbines in the future. A research team from Karlsruhe Institute of Technology (KIT) has developed a refractory metal-based alloy with properties unparalleled to date. Read on to learn more about it.

INSIDER

Research Lab

Using Ultrabright X-Rays to Test Materials for Ultrafast Aircraft

This might seem like an obvious statement, but designing an aircraft that flies at five to seven times the speed of sound is difficult. Paradoxically, materials for...

INSIDER

Motion Control

Stevens Researchers Test Morkovin's Hypothesis for Major Hypersonic Flight Breakthrough

If it were to become a reality, hypersonic flight, long the realm of science fiction, could revolutionize global travel, transforming day-long...

INSIDER

Materials

Controlling Heat Spikes in Electric Aircraft at Takeoff

Researchers at Embry‑Riddle Aeronautical University and Brazil’s Instituto Tecnológico de Aeronáutica (ITA) will combine forces on one of the main challenges of electric aircraft...

INSIDER

Materials

A New Quantum Materials Research System

Scientists at the U.S. Naval Research Laboratory (NRL) have a powerful new tool to accelerate discovery in quantum materials for advanced electronics. The laboratory recently completed installation of...

Articles

Materials

Selecting the Best Plastic for Spacecraft Applications

The purpose of this article is to present some design considerations when selecting plastics for use in spacecraft. Read on to learn more.

Briefs

AR/AI

Researchers Discover New Materials That Could Enhance Fighter Jet Efficiency

Read on to learn more about a pioneering study that sets the stage for a new era in functional alloy design — faster, cheaper, and smarter.

INSIDER

Manufacturing & Prototyping

Can Neutrons Improve 3D-Printing of Aluminum Aerospace Components?

How can particularly light yet extremely resilient aluminum components for aerospace be manufactured using industrial 3D printing?