---
title: "Italian Air Force validates 3D printed air intake component"
url: https://www.voxelmatters.com/italian-air-force-validates-3d-printed-air-intake-component/
date: 2024-07-29
modified: 2024-07-29
lang: en
author: "Edward Wakefield"
description: "On July 4, 2024, at the Aeronautical and Space Experimentation Division (DASAS) in Pratica di Mare, an experimental flight took place using an Alenia Aermacchi T-346A trainer aircraft, which was..."
categories:
  - "Aerospace AM"
  - "Defense"
  - "Italy"
  - "Metal Additive Manufacturing"
tags:
  - "insights"
image: https://www.voxelmatters.com/wp-content/uploads/2024/07/Presa_aria__Sperimentazione_aeronautica_e_spaziale_progetto-A.C.A.R.M.A._20240704-640x426.jpg
word_count: 501
---

# Italian Air Force validates 3D printed air intake component

On July 4, 2024, [at the Aeronautical and Space Experimentation Division (DASAS)](https://www.aeronautica.difesa.it/2024/07/15/sperimentazione-aeronautica-e-spaziale-concluso-con-successo-il-volo-sperimentale-del-progetto-a-c-a-r-m-a-sulla-manifattura-additiva/) in Pratica di Mare, an experimental flight took place using an Alenia Aermacchi T-346A trainer aircraft, which was equipped with a 3D printed air intake component. The DASAS, [a branch of the Italian Air Force](https://www.voxelmatters.com/beamit-signs-deal-with-leonardo-aircraft-for-am-part-production/), is responsible for research, experimentation, and testing in aeronautics and space.

This flight was the final phase of the ACARMA project (Acceptability of Aeronautical Components Made in Additive Manufacturing). The project is a collaboration between DASAS and several partners, including the Department of Civil and Mechanical Engineering at the University of Cassino and Southern Lazio (the main proponent), [BEAMIT, a company specializing in 3D printing of aeronautical components](https://www.voxelmatters.directory/company/beam-it/), and Techdyn Engineering, a spin-off company with expertise in material behavior modeling and simulation.

![Italian Air Force validates 3D printed air intake component. A successful experimental flight marks key advancement in AM for aeronautics.](https://www.voxelmatters.com/wp-content/uploads/2024/07/Presa_aria_DASAS_Sperimentazione_aeronautica_e_spaziale_progetto-A.C.A.R.M.A._20240704.jpg)

The ACARMA project focuses on using additive manufacturing technologies to create and characterize aeronautical components. In recent years, AM has significantly developed due to its advantages in production, such as reduced material waste, the ability to produce complex shapes, and the potential to redesign parts to reduce weight. It also offers operational benefits, including on-demand production of parts quickly and cost-effectively, and extending component life through innovative repair techniques.

The goal of the project is to develop and implement a methodology for characterizing and predictively analyzing components made through AM - aiming for aeronautical certification. This multiscale approach is based on targeted experimentation and numerical simulation.

The objective is to predict the mechanical behavior of a 3D printed object starting from the characteristic process parameters of the printer. This methodology was validated on a technological demonstrator - a real air intake component of the T-346A aircraft - under operational conditions. A component was selected, re-engineered, printed, and subjected to ground and flight tests. The chosen element is particularly significant for high-speed deformation characterization, which is a critical factor for this production technique.

![Italian Air Force validates 3D printed air intake component. A successful experimental flight marks key advancement in AM for aeronautics.](https://www.voxelmatters.com/wp-content/uploads/2024/07/Montaggio__Sperimentazione_aeronautica_e_spaziale_progetto-A.C.A.R.M.A._20240704.jpg)

The implementation of the ACARMA project involved collaboration within DASAS between the Aeronautical and Space Material Technologies Department, which has been involved from the initial experimental phases of material characterization and model development, and the Experimental Flight Department, which modified the aircraft by installing the experimental component and flight test instrumentation for ground and flight tests.

The Italian Air Force's Aeronautical and Space Experimentation Division is [unique in Italy](https://www.voxelmatters.com/exentis-pharma-system-delivered-to-italian-pharmaceutical-company/) as the first and only centralized structure of individual study and experimentation centers under the Armed Forces. It works in synergy with national and international aeronautical leaders - conducting studies, experimentation, testing, technical-operational evaluation, and supporting the research of new aeronautical weapon systems. This also benefits other Armed Forces and State Armed Corps when requested. Additionally, DASAS provides technical-logistical, administrative, and operational support to Air Force Entities/Departments at the airport, as well as to Entities of other Armed Forces and State Armed Corps present. It ensures the necessary services for the safe and effective conduct of flight activities and manages activities related to the reception, boarding, and disembarkation of personnel, materials, and equipment arriving and departing from Pratica di Mare airport.