Irish Manufacturing Research & Renishaw: Advancing Metal 3D Printing for Aerospace Optics

New AM collaboration Additive manufacturing boost for Ireland’s space sector

2025-07-07 Source: Irish Manufacturing Research 2 min Reading Time

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Irish Manufacturing Research and Renishaw are developing scalable metal 3D printing processes for aerospace optics, aiming to accelerate production and support Ireland’s growing space sector.

IMR and Renishaw join forces to develop advanced additive manufacturing solutions for aerospace, targeting scalable production of next-generation optical components for satellite communication.(Source: IMR) — IMR and Renishaw join forces to develop advanced additive manufacturing solutions for aerospace, targeting scalable production of next-generation optical components for satellite communication.
(Source: IMR)

Irish Manufacturing Research (IMR) announced a new collaboration with Renishaw to drive cutting-edge research in additive manufacturing (AM) for novel aerospace materials. This partnership is part of a Disruptive Technology Innovation Fund (DTIF) project led by mBryonics, a specialist in freeform optics for the space industry.

At the heart of this collaboration is the installation of a Renishaw RenAM 500Q Flex system at IMR’s advanced manufacturing facility in Mullingar. This state-of-the-art equipment is enabling IMR’s research team to develop advanced process parameters for metal 3D printing of freeform optical components — critical elements in next-generation laser-based satellite communication systems.

By shifting production from traditional machining, where parts are laboriously cut from large metal blocks to near-net-shape additive manufacturing, the project aims to significantly increase production speed and efficiency. The RenAM 500Q Flex system, equipped with Renishaw’s Tempus technology and a four-laser configuration, offers superior thermal management and process control. This is essential for successfully printing highly temperature-sensitive aerospace materials that are prone to defects like cracking during conventional laser powder bed fusion (LPBF).

“Our approach will improve build quality and enable scalability,” said Colin Meade, Additive Manufacturing Technologist at IMR. “This research isn’t just about lab-based experimentation; it’s about developing technology ready for full-scale production. Our aim is to achieve a technology readiness level (TRL) of seven or higher to support rapid industrial adoption.”

With an ambitious target to complete the project by autumn 2026, IMR’s research could help mBryonics scale its production from a handful of units each month to hundreds or even thousands, supporting Ireland’s growing aerospace sector.

“Our collaboration with IMR is about more than just supplying technology, it’s about providing the expertise and support needed to drive innovation,” added Chris Dimery, AM Business Manager (EMEA) at Renishaw. “By working closely with IMR, we’re ensuring that advanced additive manufacturing solutions are developed with real-world industrial adoption in mind.”

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