Mitsubishi Heavy Industries (MHI) has successfully qualified its first metal additively manufactured component for use in commercial aircraft engines. The fuel nozzle, produced using laser powder bed fusion, will be integrated into engines currently under development for regional jets.

The component consolidates 12 traditionally manufactured parts into a single printed piece, reducing weight by 25% and eliminating multiple welding operations. MHI’s aerospace division has invested approximately 2 billion yen in AM equipment and process development over the past three years.

“Japanese manufacturing culture emphasizes precision and reliability,” explained chief engineer Tanaka Hiroshi. “We’ve conducted extensive testing to ensure additively manufactured parts meet our stringent quality standards. This includes fatigue testing, high-temperature cycling, and real-world engine trials.”

The company is using nickel-based superalloys for high-temperature applications and titanium alloys for structural components. MHI has installed six industrial metal 3D printers at its Nagoya facility and established an AM center of excellence staffed by 40 engineers.

Japan’s aerospace AM adoption has historically lagged behind the United States and Europe, partly due to conservative certification requirements and a preference for proven manufacturing methods. However, the success of companies like MHI and Kawasaki Heavy Industries is demonstrating the technology’s viability.

MHI is also exploring AM for maintenance and repair operations. The ability to print spare parts on-demand could significantly reduce aircraft downtime and eliminate the need for large inventories of legacy components for aging aircraft fleets.

The company plans to expand its use of metal AM to landing gear components, hydraulic system parts, and cabin fixtures. Industry observers expect this success to encourage other major Japanese manufacturers to accelerate their AM adoption timelines.