Airbus Defence & Space presents three core material technologies for next‑generation aerospace structures: additive manufacturing, advanced composites, and cold‑spray repair. High‑speed imaging of Scalmalloy® laser melting illustrates how melt‑pool dynamics, spatter formation, and shielding‑gas flow affect process stability, underlining the need for tight control of feedstock quality and laser parameters. Parallel developments in large integrated CFRP structures, dry‑fiber placement, and automated bonding/welding aim to reduce manufacturing cost and increase integration. A major focus is cold spray, where a nitrogen‑based process developed with Impact Innovations enables ductile aluminum repairs without heat‑affected zones, improving adhesion and fracture behavior for non‑weldable alloys such as Al6061, Al7050, and Al2024 and supporting sustainable component life‑extension.
