The Hi-StA-Part project aimed to demonstrate the viability to produce aerospace grade aluminium parts using Direct Manufacture (DM) – specifically the process of Selective Laser Melting (SLM). The project demonstrated that components and parts can be manufactured with a significant weight reduction, to the required mechanical properties for aerospace applications.

The strategy of the project was to investigate the SLM processing of existing 7xxx (7075) series alloy powder and also using AlSc (Scalmalloy) material, which has been developed outside of the project, for processing by SLM. The 7075 Al alloy material was used to build mechanical test specimens using a state of the art 1kW SLM system (by partner TWI). As part of this activity, we investigated ‘part optimisation’; whereby part weight and materials usage can be minimised to show the true benefit of manufacturing by SLM. EADS Apworks used their own procedures and SLM systems to produce tensile, fatigue and corrosion specimens using AlSc powder material.

Throughout the project, energy and raw material usage were monitored, allowing a true and accurate comparison of the SLM process against existing manufacturing techniques to be undertaken as part of the project.

By successfully achieving the aims of this project – we demonstrated the potential for DM to manufacture Al alloy components to TRL 6. This will significantly help to maintain and improve the competitiveness of the European aerospace sector.