Innovation, performance and lightness: successful maiden flight of a complex multifunctional structure produced by MBDA using additive layer manufacturing.

Additive layer manufacturing is a key technology at MBDA, driving our capacity to innovate with disruptive concepts and deliver high-performance, competitive solutions in the defense sector. Leveraging over 10 years of experience in metal additive layer manufacturing, MBDA teams have achieved a breakthrough: the successful design and maiden flight of a complex multifunctional structural component, produced using additive layer manufacturing for major electronic equipment in a next-generation missile system. This achievement marks a first in missile application for additive layer manufacturing.

Developed in a titanium alloy using the laser powder bed fusion additive layer manufacturing process, this innovative part provides a range of new functionalities in addition to its essential structural role. Its unique additive layer manufacturing-enabled design allows electronic boards to be integrated directly into its body, optimizing assembly and improving performance. 
 

Thermal management and weight reduction through additive layer manufacturing

A significant benefit of additive layer manufacturing is its capability to optimize thermal management. By creating a double-skin structure, additive layer manufacturing provides thermal insulation, reducing internal temperature rise by up to 70%. This advanced approach also allows MBDA to dramatically reduce mass and optimize component volume, directly responding to the strict requirements of innovative missile systems
 

© MBDA 
 

Rigorous testing validates additive layer manufacturing for defence

The design and development of this multifunctional part was a result of co-engineering between MBDA’s Mechanical Engineering and Industrial departments, underpinned by advanced digital simulation tools tailored for additive layer manufacturing processes. More than 50 prototypes were produced and underwent comprehensive tests to validate fatigue resistance, thermomechanical stability, and firing performance—critical elements for military applications.

In 2025, following successful test campaigns, a missile mock-up equipped with this groundbreaking additive layer manufacturing component underwent system firing validation. The flight test was carried out successfully, confirming that additive layer manufacturing delivers the required functionality and performance in real operational conditions. 
 

Future pathways: scaling additive layer manufacturing at MBDA

The next steps for MBDA include part qualification and transition to series production, enabled by a dedicated industrial roadmap focused on additive layer manufacturing. This strategy includes developing robust additive layer manufacturing supply chains and investing in new, larger, and more efficient powder bed fusion machines—strengthening MBDA’s leadership in additive layer manufacturing for the defense industry.