ADVANCED MATERIALS & PROCESSES | MAY 2026 20 The ambition to achieve net zero emissions is driving significant change in aerospace—from propulsion systems and energy sources to the very materials and methods used to build aircraft. As the industry races to decarbonize, additive manufacturing (AM) has emerged as a transformative technology enabling that shift. TECHNICAL SPOTLIGHT SHAPING THE FUTURE OF SUSTAINABLE AVIATION THROUGH ADDITIVE MANUFACTURING AND COLLABORATION As aerospace races toward net-zero emissions, additive manufacturing has enabled the design of intricate, lightweight heat exchangers that address thermal management challenges of next-generation propulsion systems. aerospace’s biggest technical barriers to sustainability: thermal management. WHY THERMAL MANAGEMENT MATTERS FOR SUSTAINABLE AVIATION Whether powered by hydrogen fuel cells, hybrid-electric systems, sus- tainable aviation fuel or battery packs, next-generation aircraft generate sig- nificant amounts of heat. Managing that heat safely and efficiently, without adding unnecessary weight or complexity, is a challenge that directly affects the viability of sustainable aviation. Effective thermal management is critical because excessive heat can compromise both performance and safety. In hydrogen fuel cell systems, overheating can reduce efficiency and shorten component lifespan, while in battery- or hybrid-electric configurations, unmanaged heat can lead to reduced energy density, faster degradation, or even safety risks. Conventional heat exchangers are often limited by design constraints, forcing trade-offs between weight, size, and thermal performance. Additive manufacturing removes these limits, enabling intricate geometries Conflux Technology views AM as a new way to manufacture components and as a fundamental enabler of smarter, lighter, and more sustainable flight. Multiple collaborations, including projects with Airbus, Honeywell’s TheMa4HERA consortium, and AMSL Aero in the last year alone, demonstrate how AM is being used to tackle one of The Airbus’ ZEROe project focuses on delivering a commercially viable, fully electric, hydrogen- powered commercial aircraft into service.
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