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Beyond Jewelry: Cooksongold Pioneers Precious Metals in Aerospace Additive Manufacturing
The aerospace industry is constantly seeking innovative materials and manufacturing processes to enhance performance, reduce weight, and improve fuel efficiency. While precious metals have long been valued for their unique properties in electronics and other specialized applications, their potential in aerospace additive manufacturing (AM) is now being explored. Cooksongold, traditionally known for its expertise in precious metals for the jewelry industry, is now pioneering the use of these materials in aerospace AM, opening up new possibilities for designing and manufacturing critical components.
The Allure of Precious Metals in Aerospace
Precious metals like gold, silver, platinum, and palladium possess exceptional properties that make them attractive for aerospace applications. According to a report, these metals boast high melting points, excellent conductivity, superior corrosion resistance, and malleability. These characteristics are crucial for creating reliable electrical connectors, circuit boards, sensors, and other vital electronic components that must withstand the extreme conditions of space missions.
Nikesh Patel, Head of Cookson Industrial, emphasized that precious metals offer a “whole new world of design parameters compared to traditional alloys” for extreme environments like aerospace, where there is no room for compromise.
Cooksongold’s Bold Move into Aerospace AM
Cooksongold, a UK-based company with a century-long heritage in precious metals, has launched a new industrial division called Cookson Industrial to explore the usage of precious metals in AM for critical applications. This strategic move signifies a shift beyond the jewelry and luxury goods sectors, recognizing the immense potential of precious metals in high-performance industries like aerospace.
Cookson Industrial offers a comprehensive suite of services, including consultancy, research and development (R&D), new product development (NPD), and production, encompassing both conventional and additive manufacturing processes. The division operates from HM Precious Metals’ headquarters in Birmingham, UK, and aims to assist organizations in de-risking their development, simplifying supply chains, and accelerating time to market.
Driving Innovation through Collaboration
Cookson Industrial is actively collaborating with the University of Birmingham to research the development of precious metal alloys tailored for AM applications in aerospace, healthcare, and glass fiber manufacturing. This partnership has been bolstered by a £750,000 grant from the Engineering & Physical Sciences Research Council (EPSRC), demonstrating a commitment to driving innovation in the use of precious metals within the AM sector.
Targeting Satellite Thruster Design
One of Cookson Industrial’s key focus areas in the aerospace market is the development of satellite thruster designs. By leveraging precious metal AM, the company aims to create significantly lighter components and reduce the volume of hazardous materials, such as hydrazine, traditionally used in chemical thrusters.
The Advantages of Precious Metal AM in Aerospace
The integration of precious metals into aerospace AM offers several compelling advantages:
- Enhanced Performance: Precious metals can withstand extreme temperatures and harsh environments, ensuring the reliable operation of critical components.
- Weight Reduction: AM enables the creation of lightweight designs with intricate lattice structures, improving fuel efficiency and payload capacity.
- Corrosion Resistance: Precious metals exhibit exceptional corrosion resistance, minimizing the risk of electrical failures and ensuring long-term reliability.
- Design Flexibility: AM allows for the creation of complex geometries and customized designs that were previously impossible to manufacture, opening up new possibilities for innovation.
- Reduced Material Waste: AM builds parts layer by layer, using only the necessary material, minimizing waste and improving cost-effectiveness, especially when working with expensive precious metals.
Challenges and Opportunities
While precious metal AM holds immense promise, there are also challenges to address:
- High Material Costs: Precious metals are inherently expensive, which can impact the overall production cost of aerospace components.
- Limited Material Selection: The range of precious metal alloys currently available for AM is relatively narrow, requiring further research and development.
- Quality Consistency: Ensuring consistent quality and mechanical properties in AM-produced parts, especially with precious metals, requires stringent process control and quality assurance measures.
Despite these challenges, the opportunities for precious metal AM in aerospace are vast. As technology advances and costs decrease, the use of these materials is expected to expand, driving innovation and enabling the development of next-generation aerospace components.
The Future of Precious Metals in Aerospace
The aerospace industry’s demand for precious metals is projected to increase in the coming years, driven by factors such as the expansion of commercial space travel, advancements in fuel-efficient aircraft design, and the growing emphasis on sustainable aviation.
Industry analysts predict that the market for precious alloys in AM will become a major segment in metal 3D printing, with material revenues alone topping $250 million by 2028 and overall precious metal AM-related revenues nearing $2 billion at the end of a 10-year forecast period.
Conclusion
Cooksongold’s pioneering efforts in precious metal AM for aerospace represent a significant step forward in materials innovation. By leveraging the unique properties of these metals and the design freedom of AM, the company is paving the way for lighter, more durable, and higher-performing aerospace components. As the aerospace industry continues to push the boundaries of innovation, precious metals are poised to play an increasingly critical role in shaping the future of flight.
If you’re interested in exploring the potential of precious metals in aerospace additive manufacturing, contact us today for a consultation.