Today at the Asia 3D Printing & Additive Manufacturing Expo (TCT Asia) in Shanghai, a compact workstation showcased an Additive Friction Stir Deposition (AFSD) system. Through “magical technology,” the equipment “printed” component after component, vividly demonstrating its exceptional performance in manufacturing complex structures. It instantly became the star attraction of the exhibition. Developed jointly by Aerospace Engineering Equipment (Suzhou) Co., Ltd.—a subsidiary of Shanghai Aerospace No. 149 Factory—and the Institute for the Development and Quality, Macau, this newly upgraded system marks a major breakthrough for China in the field of Additive Friction Stir Deposition (AFSD) manufacturing.

In recent years, Aerospace Engineering Equipment (Suzhou) Co., Ltd. has focused its research and application efforts on Additive Friction Stir Deposition (AFSD), pioneering new approaches for the processing and manufacturing of high-performance large-scale metal components in aerospace, aviation, and marine sectors.

AFSD technology is an Additive Friction Stir Deposition (AFSD) manufacturing technique based on the principle of friction stirring. It serves as a “golden key” to unlocking the field of Additive Friction Stir Deposition (AFSD) manufacturing. Its core mechanism involves generating heat through friction between a rotating tool head and metallic raw material at temperatures below the material's melting point. This process softens the material to a plastic state, enabling layer-by-layer deposition and compaction onto the substrate to form a “dense” three-dimensional structure.

“ AFSD, as a derivative technology of Friction Stir Welding (FSW), possesses its core advantages,“ explained Professor Lap Mou Tam, Chief Scientist at Aerospace Engineering Equipment (Suzhou) Co., Ltd. and Professor at the University of Macau. ”It avoids defects common in traditional fusion-based additive manufacturing processes like laser and arc additive manufacturing—such as porosity, cracks, and coarse microstructure—while offering a smaller heat-affected zone that significantly reduces deformation risks. "Consequently, large-scale, high-performance metal components fabricated using AFSD technology exhibit more stable forming quality, superior product performance, and optimized cost control. The resulting forged microstructure surpasses that of castings and welded components, and can even approach or exceed the quality of forged parts, holding significant potential to drive industrial advancement. Additionally, AFSD technology offers significant advantages in energy conservation and emissions reduction, with carbon emissions reduced by over 40% compared to traditional fusion welding, aligning more closely with the characteristics of green manufacturing.

“AFSD technology isn't just taking to the skies—we're also setting our sights on the seas,” said Wang Hu of Aerospace Engineering Equipment (Suzhou) Co., Ltd. “Currently, many high-tech enterprises are focusing their efforts on building new productive forces, urgently seeking breakthroughs in manufacturing high-performance metal components.”

At the exhibition site, the 3.35-meter-long rocket fuel tank bottom drew crowds of visitors and industry peers to stop and observe. This tank bottom was precisely printed using AFSD technology, leaving everyone in awe of its technical prowess. It is reported that AFSD technology will shine brightly in the aerospace sector, enabling the production of large structural components such as satellite adapters and rocket tank bottoms. This technology fulfills the need for weight reduction and efficiency gains in large structural parts, lowers production costs and cycles, and significantly enhances product quality and reliability. In the maritime sector, AFSD technology also demonstrates immense application potential. Key structural components such as large ship hulls and propellers manufactured using this technology exhibit excellent efficiency and durability, enhancing navigation performance.

“Beyond manufacturing, we can also repair components, not only minimizing the heat-affected zone during the repair process but also extending the service life of critical parts,” explained Wang Hu. “Specifically, the rapid repair of damaged ship components shortens maintenance cycles while reducing repair costs.” Additionally, Aerospace Engineering Equipment (Suzhou) Co., Ltd. has applied AFSD technology to the production of novel materials and structures such as gradient materials and composites. This enables integrated manufacturing of functional structures, meeting the high-performance demands of both materials and components.

AFSD technology has sparked a global wave of enthusiasm, with research institutions and enterprises worldwide actively developing its research and applications. In 2022, Aerospace Engineering Equipment (Suzhou) Co., Ltd. collaborated with the Institute for the Development and Quality, Macau to successfully develop China's first continuous rod-feeding, engineering-grade Additive Friction Stir Deposition (AFSD) equipment. This achievement positions China as the second country after the United States to master the full engineering capabilities of this technology.

Today, Aerospace Engineering Equipment (Suzhou) Co., Ltd. has overcome key technological challenges including hybrid heat source Additive Friction Stir Deposition (AFSD), high-precision closed-loop control, and heterogeneous material composite additive manufacturing. This breakthrough enables product development using metal alloy materials such as aluminum, magnesium, copper, and titanium. Taking satellite adapters manufactured using AFSD technology as an example, these products achieve mechanical properties equivalent to forged Series 2 aluminum alloys and meet Grade A standards in ultrasonic testing. The manufacturing cycle is reduced by 60%, and production costs are lowered by over 30%, providing robust support for the advancement of China's aerospace industry.