Thin-Walled Jet Engine Exhaust and Beyond: Unlocking the Potential of Blown Powder Laser Metal Deposition
As industries push the boundaries of performance, efficiency, and sustainability, advanced manufacturing technologies like Laser Directed Energy Deposition (L-DED) are stepping into the spotlight. This article showcases the development of a thin-walled jet engine exhaust using blown powder LMD, and explores how this flexible, scalable process is opening new possibilities across aerospace, oil & gas, and beyond.
Project Overview
Developed for a small experimental jet engine, the component features:
- Outer Diameter: 112 mm
- Wall Thickness: 1 mm
- Length: 120 mm
- Material: Inconel 625 – a high-performance nickel-based superalloy
Using a single-wall spiral build strategy on a rotary tilt manipulator, the part was manufactured in just 8 hours, achieving a near-net shape with minimal post-processing.
Why Blown Powder LMD?
Blown powder LMD was selected for its unique advantages:
- Low Heat Input: Ideal for thin-walled structures, reducing distortion and residual stress.
- Rapid Build Time: Significantly faster than casting or forging.
- Material Efficiency: Minimal waste due to near-net shape production.
- Design Flexibility: Geometry can be modified quickly without retooling, enabling rapid iteration and customisation.
This flexibility is especially valuable in R&D environments or when adapting to evolving customer requirements.
Scalability and Future Applications of LMD
The same process is scalable to components up to:
- 1.4 metres in diameter
- 1.5 metres in height
This opens the door to larger propulsion systems, auxiliary power units, and structural aerospace parts.
Cross-Industry Use Cases for Thin-Wall LMD
🔩 Oil & Gas
- Downhole Tools: Corrosion-resistant sleeves and housings for harsh environments.
- Valve and Pump Housings: Lightweight, pressure-resistant components.
- Heat Exchanger Shells: Thin-walled, high-surface-area structures with optimised flow paths.
✈️ Aerospace & Defence
- UAV Exhausts and Ducting: Lightweight, high-temperature components for drones and small aircraft.
- Satellite Structures: Thin-walled brackets and shielding with excellent strength-to-weight ratios.
🚗 Automotive & Motorsport
- Turbocharger Housings: High-performance, thermally stable parts.
- Battery Cooling Plates: Custom cooling geometries for electric vehicles.
🏭 Industrial Applications
- Custom Ducting: Corrosion-resistant piping for chemical and process industries.
- Tooling Shells: Lightweight moulds with integrated cooling for rapid prototyping.
🔧 Repair and Retrofit
- Component Rebuilds: Restore worn or damaged thin-walled parts with precision and minimal downtime.
