#246 ATI's Alex Hickson & Matthew Bailey on the 'Fantastic Economic Opportunity' For AM in Aerospace

Why It Matters

AM could unlock billions in aerospace savings while cutting emissions, reshaping the sector’s competitive landscape. ATI’s roadmap provides a blueprint for manufacturers to capitalize on this shift and meet climate commitments.

Key Takeaways

• ATI’s 2024 AM strategy targets multi‑billion‑dollar market growth
• Additive manufacturing reduces aircraft weight and fuel consumption
• Regulatory certification remains a key barrier for AM parts
• Supply‑chain resilience improves with on‑demand component printing
• Industry collaboration essential to meet 2050 net‑zero targets

Pulse Analysis

Additive manufacturing is rapidly moving from niche prototyping to full‑scale production in civil aerospace, driven by its ability to create complex geometries that traditional machining cannot achieve. The technology promises up to 30% weight savings on critical components, translating into lower fuel burn and operating costs. Across the Atlantic and Europe, aerospace OEMs are investing heavily in metal‑laser powder‑bed fusion and electron‑beam additive processes, positioning AM as a cornerstone of next‑generation aircraft design.

The Aerospace Technology Institute’s 2024 additive manufacturing strategy set an ambitious economic target: to capture a multi‑billion‑dollar share of the global aerospace AM market within the next decade. Since its launch, ATI has funded over 20 collaborative projects, accelerated certification pathways, and established a national AM testbed that enables rapid iteration of aerospace‑grade parts. These initiatives have already demonstrated cost reductions of up to 25% for low‑volume production runs, signaling a clear return on investment for manufacturers willing to adopt the technology.

Beyond cost, AM is integral to the industry’s net‑zero by 2050 commitment. By enabling lighter structures and consolidating part counts, additive processes can cut lifecycle emissions dramatically. However, scaling up requires harmonized standards, robust supply‑chain logistics, and skilled workforce development. ATI’s call for broader industry participation underscores the need for shared data, joint certification efforts, and public‑private partnerships to unlock the full environmental and economic benefits of additive manufacturing in aerospace.