Discover how Aurora Flight Sciences is advancing aircraft design by experimenting with cutting-edge materials and manufacturing methods—from metal 3D printing to innovative composite techniques—in pursuit of lighter, stronger, and more efficient aerospace components. Read more > >
The selection of materials is crucial in the aircraft design process, directly influencing performance, safety, and efficiency. At Aurora Flight Sciences, the Materials, Processes, and Testing (MP&T) engineering team leads the way in defining material requirements and selecting optimal materials for aircraft components. Working at the forefront of technology, the MP&T team is constantly exploring new materials and manufacturing techniques to meet the demands of modern aircraft design.
Aurora’s experimental aircraft programs provide an opportunity to explore cutting-edge materials not commonly used in aerospace, such as metal 3D printing. This technique allows for the creation of complex parts with intricate geometries, which would be difficult or impossible to produce with traditional methods. The MP&T team conducts thorough testing to ensure these parts meet stringent aerospace standards.
Additionally, Aurora is pushing the boundaries of composite materials like carbon fiber by experimenting with non-conventional manufacturing methods, including adhesive bonding and resin infusion. These methods help optimize the balance between weight and strength in key structural components, such as wing spars.
By using rapid prototyping techniques like 3D printing and automated fiber placement, Aurora’s engineers can quickly test new materials and manufacturing processes on a practical scale. With rigorous testing at extreme temperatures and magnification levels, the MP&T team ensures that every material and process meets the high standards required for next-gen aerospace technology.
