Aerospace 3D printing projects raise output, save money and encourage innovation. People primarily choose metals for this application due to their durability and versatility. What are some of the most frequently chosen options that boost fabrication efficiency?
1. 316L Stainless Steel
316L stainless steel is a low-carbon version of the 316 variety. This material’s corrosion resistance and suitability for high-temperature environments make it popular for manufacturing and other industries that require strong, tough components. Despite aerospace 3D printing becoming more widely used, uncertainties exist about how some metals will respond during production.
That challenge encouraged one team to use artificial intelligence to clarify the characteristics of 3D-printed parts from 316 stainless steel. A central part of this project involves creating AI simulations to predict component performance. Comparing the physical items with the simulated ones finds discrepancies. Additionally, the researchers will use metal grain sizes smaller than 1 micron to achieve better precision.
The project’s first creation will be a naval propeller. However, those overseeing it envision numerous other applications, including aerospace 3D printing. Streamlining and perfecting the process increases potential adoption rates as more decision-makers realize how newer fabrication options solve existing pain points. For example, International Space Station workers could get parts without resource-intensive launches by making them on-site.
2. Nickel Superalloy H282
Some companies specialize in metal 3D printing for large, mission-critical parts. One is Velo3D, which has partnered with brands such as Lockheed Martin and SpaceX to support innovation goals.
In April 2025, that company purchased a new 3D printer to expand its additive manufacturing capabilities. This one creates parts from nickel superalloy H282, a metal for high-temperature applications, such as propulsion systems and nuclear power plants.
Velo3D executives explained that creating with nickel superalloy H282 brings many benefits, such as thermal stability, strength and fabricability. These advantages in a single material make this metal an excellent choice for aerospace 3D printing.
People overseeing other specialized applications must consider the desired characteristics, too. 3D printing has become a popular way to address the housing shortage and create less-expensive residences quickly. Crews only need 48 hours to print structural frames for small houses. Concrete and wood are among the most widely used materials.
3. Inconel
The emerging nature of aerospace 3D printing enables exploration during the material-selection stage. Dr. Martin White, director for technical operations for the Global Advanced Manufacturing Programs Division at ASTM International, explains, “In short, all metallic technologies are being considered. The target is always to achieve a sustainable business case through calculated cost reduction or through performance gains.”
Inconel is the umbrella term for a trademarked group of nickel-chromium-based superalloys that perform well in environments featuring high temperatures or above-average mechanical loads. These characteristics attract attention from engineers who are choosing the best materials for mission-critical projects.
In August 2025, news broke of Agnikul Cosmos —a private Indian space company — creating the largest single-piece 3D-printed rocket engine from Inconel. The component measures more than 1 foot long and has no welds, fasteners or joints. That design reduces complexity and shortens production time frames. The metal can also tolerate the extreme temperatures of rocket launches, ensuring consistent reliability.
Advancing Aerospace 3D Printing
These metals have proven their worth for demanding uses such as aerospace parts. As this fabrication method gains ground, engineers will continue to push the boundaries by using the materials for new components or investigating which alternatives might better align with stated goals.
