Laser DED additive manufacturing: Aerospace air mixer

Developing an air mixer duct in a nickel-based alloy requires combining highly complex internal channel geometries with a robust tubular structure. The aim is to overcome the limitations of traditional rolled-and-welded solutions by improving design freedom, material performance and production rate alike.

IREPA LASER has implemented a hybrid approach combining PBF for the complex internal areas and powder-fed laser DED for the tubular elements and interfaces. This strategy relies on an integrated digital chain ensuring geometric consistency and repeatability of the manufacturing steps.

Producing this part requires controlling the interaction between two additive manufacturing processes within a single architecture. Control of internal geometries and overall process stability are essential to achieve a level of quality compatible with aerospace requirements.

The solution enables the manufacture of a functional part meeting aerospace sector requirements within a controlled hybrid architecture. This approach significantly improves industrial robustness and reduces scrap compared with a conventional rolled-and-welded solution.