Additive manufacturing of high-stress aerospace components in refractory metals, nickel superalloys and titanium using the LPBF process
Thrustworks
New on Amplifa
About Thrustworks
Thrustworks is a specialized contract manufacturer for additively manufactured metal components with a focus on aerospace and energy technology. The company covers the complete process chain: from AM design optimization and parameter development through Laser Powder Bed Fusion (LPBF) printing in a temperature- and humidity-controlled environment to post-processing with heat treatment (stress relief, homogenization, HIP), surface treatment, CNC machining and cleaning. The offering is rounded out by quality control with destructive and non-destructive testing as well as material analysis and component validation according to aviation standards. Production is carried out in difficult-to-machine specialty materials such as refractory metals (C-103, niobium, tantalum, tungsten), nickel superalloys (In718, In625, Hastelloy X), titanium (Ti6Al4V), stainless steels (316L, 17-4 PH) and aluminum alloys. Thrustworks is part of The Exploration Company and contributes to a full-stack approach for space infrastructure in which propulsion technology is developed together with spacecraft, software and mission operations.
- Processes
- Laser Powder Bed Fusion (LPBF), AM Design Optimization (Engineering & Design Support), Parameter Development & Slicing, Heat Treatment (Stress relief, Homogenization, HIP), Surface Treatment & Coatings, Machining (CNC, grinding), Cleaning & Inspection, Destructive & non-destructive testing (DT/NDT), material analysis according to aviation standards
- Materials
- Niobium Alloy C103, Pure Niobium, Pure Tantalum, Pure Tungsten, Inconel 718, Inconel 625, Hastelloy X, Ti6Al4V (Titanium Grade 5)
- Industries
- Aerospace, Energy technology
- 01
AM design optimization
- 02
Parameter development & slicing
- 03
LPBF 3D printing
- 04
Heat treatment (stress relief, homogenization, HIP)
- 05
Surface treatment & coating
- 06
CNC machining & grinding
- 07
Cleaning & inspection
- 08
Destructive and non-destructive testing (DT/NDT)
Materials and Processes
Niobium Alloy C-103
Refractory metal alloy for components in extremely hot and corrosive environments.
Pure Niobium
For applications with the highest requirements for temperature and corrosion resistance.
Pure Tantalum
High-temperature-stable refractory metal for extreme operating environments.
Pure Tungsten
Refractory metal with a very high melting point for thermally highly stressed components.
Inconel 718
Nickel superalloy for strength-critical parts at high temperatures.
Inconel 625
Nickel alloy with high corrosion and temperature resistance.
Hastelloy X
Nickel superalloy for gas turbine and aerospace applications.
Titanium Grade 5 (Ti6Al4V)
Light, strong material with a good strength-to-weight ratio for lightweight components.
Stainless Steel 316L
Corrosion-resistant stainless steel for structural components.
Stainless Steel 17-4 PH
Precipitation-hardening stainless steel for high-load precision parts.
Aluminum Alloys
Light metal for weight-reduced components in complex geometries.
Laser Powder Bed Fusion
Precise metal 3D printing process, also for sensitive materials in a controlled environment.
Components
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Laser Powder Bed Fusion (LPBF)Additive | – | – | – | – | Niobium Alloy C103, Pure Niobium, Pure Tantalum, Pure Tungsten, Inconel 718, Inconel 625, Hastelloy X, Ti6Al4V (Titanium Grade 5), 316L Stainless Steel, 17-4 PH Stainless Steel, niobium alloys, nickel alloys, titanium alloys, refractory |
| AM Design Optimization (Engineering & Design Support)Engineering | – | – | – | – | – |
| Parameter Development & SlicingEngineering | – | – | – | – | – |
| Heat Treatment (Stress relief, Homogenization, HIP)Heat treatment | – | – | – | – | – |
| Surface Treatment & CoatingsSurface | – | – | – | – | – |
| Machining (CNC, grinding)Machining | – | – | – | – | – |
| Cleaning & InspectionTesting | – | – | – | – | – |
| Destructive & non-destructive testing (DT/NDT), material analysis according to aviation standardsTesting | – | – | – | – | – |
Additional services
Reference customers
History
Thrustworks becomes part of The Exploration Company and contributes to a full-stack approach for space infrastructure.