Case Study: Thales Alenia Space achieves 25% lighter parts and half the production time with 3D Systems' Direct Metal Printing

Thales Alenia Space - Customer Case Study

Thales Alenia Space, a leading aerospace supplier, partnered with 3D Systems to prove that direct metal printing (DMP) can meet the strict quality, tolerance and performance demands of mission‑critical satellite hardware. The challenge was to produce four individualized titanium antenna brackets—mounted on shaped reflector edges—using a certified, repeatable process suitable for risk‑averse aerospace applications.

3D Systems’ On Demand Manufacturing team used design‑for‑manufacturability and topological optimization, printing the LaserForm Ti Gr23 parts on a ProX DMP 320 and delivering validated flight components. The result: brackets that are 25% lighter with improved stiffness‑to‑weight, production time cut to 4–5 weeks from 10, significant cost reductions, and rapid scale‑up (50+ components produced with plans to double output), demonstrating DMP’s viability for aerospace production.

Thales Alenia Space

Malcolm Gladwell

Thales Alenia Space