In aerospace and defense, weight reduction has always been a defining challenge. Every kilogram saved can extend flight range, increase payload capacity, or reduce fuel consumption. For aircraft and defense systems, these gains translate directly into operational performance and mission success.

Traditional manufacturing methods, however, impose constraints. Machining and casting can remove or shape material, but they are limited by tool access, draft angles, and mold design. These restrictions prevent engineers from fully optimizing weight-to-strength ratios and often lead to designs that compromise between manufacturability and performance. Metal additive manufacturing (AM) breaks through these limitations by giving engineers unprecedented design freedom.

Design Freedom with Topology Optimization

Additive manufacturing builds parts layer by layer directly from digital models, which means designs are not constrained by casting dies or traditional machining limits. This opens the door for topology optimization, where computational algorithms remove unnecessary material while preserving mechanical performance.

With AM, engineers can incorporate advanced design features such as:

• Internal lattice structures that reduce mass while maintaining stiffness.
• Variable wall thicknesses tailored to localized loads.
• Conformal channels for optimized thermal management and fluid flow.

These features, impossible or impractical with conventional manufacturing, enable aerospace and defense engineers to create parts that are lighter, more efficient, and more durable under extreme operating conditions.

Materials for Aerospace and Defense

Material selection is central to lightweighting strategies. At Nikon SLM Solutions, our systems process high-performance alloys widely used in aerospace and defense applications.

• Titanium alloys (Ti-6Al-4V): Known for their high strength-to-weight ratio and corrosion resistance, titanium alloys are ideal for structural and load-bearing parts such as brackets, wing components, and landing gear elements.
• Aluminum alloys (AlSi10Mg): These alloys combine lightness with excellent thermal conductivity, making them suitable for housings, heat exchangers, and other components where both weight and thermal performance matter.
• Nickel-based superalloys (Inconel 718, 625): These materials maintain mechanical strength and fatigue resistance at elevated temperatures, supporting propulsion systems and high-heat aerospace environments where conventional alloys would degrade.

By combining the right alloy with an AM-optimized design, engineers can achieve performance targets that exceed traditional manufacturing limits.

Part Consolidation and Reliability

Lightweighting is not just about removing material. It also involves rethinking how components are designed and assembled. Metal AM enables part consolidation, where multiple traditionally manufactured components are merged into a single structure.

For example, a bracket that would normally require machining, welding, and fastening of several subcomponents can be produced as a single AM-built part. This approach reduces weight by eliminating redundant material and fasteners while also improving reliability. Every fastener, weld, or joint represents a potential point of failure. By consolidating parts, engineers reduce these risks, resulting in components that are stronger, more durable, and easier to qualify for mission-critical use.

Moving from Prototype to Production

Aerospace and defense organizations are increasingly moving beyond prototyping and toward serial production of lightweight AM parts. Qualification processes for materials, machines, and geometries remain rigorous, but advances in process monitoring and repeatability are accelerating adoption. Nikon SLM Solutions provides the tools to support this transition, including multi-laser systems for higher throughput, open parameter access for material development, and large build envelopes for full-scale production parts.

Strategic Advantages for Aerospace and Defense

Lightweighting with AM delivers benefits that extend far beyond weight savings. Aircraft with optimized AM parts consume less fuel, reducing both cost and environmental impact. Defense systems that integrate lighter, stronger components become more agile, durable, and mission-ready. Maintenance cycles can be extended thanks to fewer part failures and longer service life.

For engineers, AM represents a shift in design philosophy — one where parts are created based on what is structurally and functionally optimal, not just what is possible with conventional tools.

At Nikon SLM Solutions, we are committed to enabling this transformation. By providing advanced AM systems, application expertise, and material flexibility, we empower aerospace and defense engineers to design the next generation of lightweight, high-performance components.

Why Partner With Nikon SLM Solutions?

For aerospace and defense manufacturers aiming to unlock the full potential of metal additive manufacturing, Nikon SLM Solutions provides the technology, expertise, and flexibility needed to succeed. Our flagship NXG series delivers industry-leading build volumes and multi-laser configurations, enabling the efficient production of large, complex structures while maintaining the precision required for mission-critical components.

We also offer versatile solutions such as the SLM®500 and SLM®280, designed for smaller builds, rapid material development, and specialized applications. Each system is engineered for precision, efficiency, and material versatility, giving manufacturers the ability to tailor their production strategy to specific program requirements.

To help engineers select the right platform, our machine comparison tool provides a side-by-side overview of system capabilities, making it easier to evaluate trade-offs between build size, throughput, and material options. Whether the goal is high-volume production, intricate lightweight structures, or the qualification of advanced alloys, Nikon SLM Solutions offers a path forward.

By partnering with us, aerospace and defense organizations gain access to advanced manufacturing solutions that improve operational readiness, enhance component performance, and drive innovation across military and aerospace technology.

Our Mission, to Empower Yours

To learn more about how Nikon SLM Solutions can help you optimize your manufacturing processes, please contact our team.