REMASTER - REpair Methods for Aerospace STructures using novEl pRocesses

Aerospace engine manufacturers earn over half their revenue from repairing high-value components, and this project aims to use 3D printing to fix damaged parts instead of replacing them. Currently, additive manufacturing—the industrial term for 3D printing—is used mainly to make new parts. This project shifts the focus to repair. The consortium, including the University of Sheffield and several industrial partners, will first remove damage from expensive components like turbine blades or casings, then use additive technologies to restore the original geometry and material performance. Developing new materials is essential to ensure the repairs hold, and the team will also explore novel joining techniques to bond the printed material to the original part. If successful, this approach could cut waste and cost in aerospace aftermarket services, which already account for the majority of engine manufacturers’ revenue. The £3.57 million, three-year project targets a practical manufacturing challenge rather than fundamental science. The immediate impact would be on industrial supply chains and maintenance operations—systems most passengers never see, but which keep aircraft flying safely and economically.