In the power2AM research project, Paderborn University is working with leading industrial partners to develop innovative solutions for implementing additive manufacturing in safety-critical helicopter drive components. The aim is to develop a stringent, industrially transferable and approvable SLM process with integrated in-situ monitoring that meets the high requirements of aviation. The focus is not only on technical aspects, but also on economic, ecological and regulatory aspects.

The project includes the selection of suitable materials, the definition of process-relevant parameters and the development of quality assurance concepts, including non-destructive testing methods and melt pool monitoring. A digital twin is used to fully integrate design, production and monitoring. The developed prototypes undergo extensive series of tests - from basic tests and endurance tests to realistic gearbox tests.

In addition, the potential of additive manufacturing in terms of resource efficiency, CO₂ savings and shorter production times is analyzed. power2AM thus makes a significant contribution to the sustainable further development of aviation and at the same time creates new impetus for the industrial use of additive manufacturing technologies in the high-performance sector.