The development speed of space propulsion components benefits largely by the increased use of Additive Manufacturing technologies like Laser Powder Bed Fusion (LPBF). Compared to conventional manufacturing routes, the development times for new component applications can be cut from years to months. However, alloys currently available and qualified for AM are limited in terms of maximum operational temperatures. Alloys with higher performance at elevated temperatures are often characterized by narrow and sensitive processing windows in LPBF, requiring experimental equipment that is not industrially suitable like, e.g., high temperature preheatings. Even then obtaining defect-free materials can be a major challenge.

In the talk we will present our progress in the maturation and qualification of the new high-temperature nickel-base alloy VDM780 for LPBF. This material is a derivate of the widespread alloy IN718 but with potentially up 100 °C higher permissible service temperatures – at the same level of LPBF processability on commercially available LPBF systems. We will present the results from the characterization of microstructures over tailored heat treatment cycles to the fabrication of demonstrator components that have been hot gas tested on DLR’s unique test benches. This talk will not only give insights into a promising new alloy candidate for Additive Manufacturing in space propulsion but will also point out the great potential of AM for accelerating innovations.

As additive manufacturing moves from niche to necessity in the aerospace sector, the challenge lies not only in technical capability but in qualification, standardisation and supply chain maturity. This expert panel brings together leaders from across industry and research to explore the path to scalable aerospace AM — from high-temperature alloys and accelerated fatigue testing to collaborative roadmaps for UK manufacturing. Join the discussion on the materials, processes and partnerships reshaping how we design, test and fly with additive.