Additive Layer Manufacturing


The Additive Manufacturing (ALM) market is expanding year on year. It offers new possibilities for component production, allowing complex shapes to be created through rapid design iteration and topological optimisation. ALM demonstrates cost advantage by only using what is necessary.

At Assystem Technologies, we have worked with our clients and partners across the turbo-machinery and aerospace industries on a number of ALM projects by implementing techniques such as Selective Laser Sintering (SLS), Selective Laser Melting (SLM) and Electron Beam Melting (EBM). We have even secured a number of patents for designs of components manufactured using ALM. Some of the projects we have worked on include:

  • Identification of components within a wing structure that can be improved upon, such as; weight reduction, material optimisation, reducing time spent on assembly and in-service repairs
  • Design and production of engine components with integrated instrumentation to avoid intrusion in air flow and provide more reliable results
  • Reduction of weight and cost of aircraft cabin seat frames using EBM, without compromising integrity

The ALM process also gives our clients increased knowledge and understanding of how topology optimisation and post-processing can assist with other areas of design and development.


  • Cost reduction
  • Reduces material usage and wastage
  • Reduces manufacture time and difficulties of complex features (e.g. scalloping, hollowing structures, thinning casings)
  • Fewer assembly parts are required, reducing assembly time and improving integrity
  • No tooling cost – the part can be changed straight away and manufactured in ‘batches of one’ with no effect on lead time
  • Weight optimisation opportunities (through additive rather than subtractive manufacturing)