At the Asia 3D Printing & Additive Manufacturing Expo (TCT Asia), an Additive Friction Stir Deposition (AFSD) workstation “printed” components on-site using the AFSD process. This live demonstration vividly showcased the equipment's exceptional capabilities in manufacturing complex structures, instantly making it the star attraction of the exhibition.

This equipment represents a newly upgraded solution jointly developed by Aerospace Engineering Equipment (Suzhou) Co., Ltd. and the Institute for the Development and Quality, Macau, tailored to market demands. Additionally, over 20 products manufactured using Additive Friction Stir Deposition (AFSD) technology—including satellite adapters, launch vehicle fuel tank bottoms, and unmanned vessel hulls—were simultaneously showcased at TCT Asia. This demonstrates the broad application prospects of AFSD technology in high-end manufacturing, where new equipment, new materials, and new technologies to forge new productive forces, opening new avenues for the processing and manufacturing of high-performance large-scale metal components in aviation, aerospace, and marine sectors.

Promote the transformation and upgrading of the manufacturing sector

Empowering Green Development

AFSD technology is an Additive Friction Stir Deposition (AFSD) manufacturing technique based on the principle of friction stirring. Its core process involves generating heat through friction between a rotating tool head and metal raw material at temperatures below the material's melting point. This 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. According to reports, this technology avoids defects commonly found in traditional fusion additive manufacturing processes such as laser additive manufacturing and arc additive manufacturing—including porosity, cracks, and coarse microstructure. Instead, it features a minimal heat-affected zone, significantly reducing deformation risks.

Precisely for this reason, large-scale, high-performance metal components produced using AFSD technology exhibit more stable forming quality, superior product performance, and optimized cost control. The forged microstructure formed through this process surpasses that of castings and welded components, approaching or even exceeding the level of forged parts, thereby offering significant potential to drive industrial advancement. AFSD technology also demonstrates notable 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.

Demonstrate hardcore capabilities

Opening a New Chapter in Key Areas

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. AFSD technology is poised to make a significant impact in the aerospace sector. It enables the production of large structural components such as satellite adapters and rocket tank bottoms, achieving weight reduction and efficiency gains for large structures. This approach lowers production costs and cycle times while substantially enhancing product quality and reliability.

In the maritime sector, AFSD technology also demonstrates significant application potential. Key structural components such as hulls and propellers for large vessels manufactured using this technology exhibit excellent efficiency and durability, enhancing navigation performance.

Beyond manufacturing, AFSD technology can also repair components, not only minimizing the heat-affected zone during the repair process but also extending the service life of critical parts. Currently, AFSD technology has been successfully applied to the production of novel materials and structures such as gradient materials and composites, enabling integrated functional and structural manufacturing to meet the high-performance demands of materials and components.

Enhance international competitiveness

Developing a Chinese Solution

At the exhibition site, spectators couldn't help but wonder as they watched the equipment operating nonstop: “After running for so long, why hasn't it paused to add raw materials?” To boost production efficiency, the developers installed a material hopper inside the equipment, allowing multiple rods to be loaded at once for continuous feeding.

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. The company has thus become the first domestic enterprise to master continuous rod-feeding AFSD technology.

Aerospace Engineering Equipment (Suzhou) Co., Ltd. has also 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 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.