The aerospace industry’s in the middle of a real shake-up, thanks to wild new manufacturing tech. Renishaw, a global engineering and scientific technology company, joined forces with Irish Manufacturing Research (IMR) to change how we make freeform optical components for satellite communications.
They’re leaning into metal additive manufacturing—specifically, the RenAM 500Q Flex system. The goal? Faster, more efficient processes that could open the floodgates for scaling up and innovating in aerospace optics. Ambitious, right?
Streamlining Aerospace Optics Manufacturing with Additive Technology
This partnership is part of a Disruptive Technology Innovation Fund project. mBryonics, a photonics company based in Ireland, leads the charge in next-gen satellite optics.
The big idea is to move away from old-school machining for aerospace optical components and dive into advanced additive manufacturing. Freeform optics, which play a huge role in satellite communications, need to be precise and tough enough for harsh environments.
But traditional manufacturing just can’t keep up. It’s slow, clunky, and doesn’t scale well—kind of a bottleneck for the whole field.
The Role of the RenAM 500Q Flex System
At the heart of all this is the RenAM 500Q Flex. This machine is built for metal 3D printing, and it’s got a four-laser setup with Renishaw’s TEMPUS process control tech.
That combo lets you really dial in the thermal conditions while printing. Normally, laser powder bed fusion systems struggle with thermal fluctuations, which can mess up your parts. The RenAM 500Q Flex keeps things steady, so you get better quality and faster builds.
Key advantages of the 500Q Flex:
- Less thermal fluctuation, so fewer defects.
- Scales up for big manufacturing runs without breaking a sweat.
- Handles aerospace-grade materials that can’t tolerate wild temperature swings.
Research Collaboration to Unlock Full-Scale Manufacturing
IMR’s Dublin facility is where they’re working on new process parameters for additive manufacturing of freeform optical components. Renishaw and IMR are teaming up to tackle issues that have stalled aerospace manufacturing for years.
They’re building a manufacturing ecosystem that can grow from small batches to full-on high-volume production. That’s not a small feat, if you ask me.
Looking Ahead: Autumn 2026 Completion
The project aims to wrap up by autumn 2026. Colin Meade, Additive Manufacturing Technologist at IMR, says they’re focused on improving build quality and finding ways to scale up.
With the groundwork in place, mBryonics could ramp up production from just a few units per month to hundreds—or maybe even thousands. That’s a game-changer for Ireland’s aerospace scene.
Expected outcomes by 2026:
- Better build quality for aerospace parts.
- Manufacturing processes that are ready for scale.
- Ireland pushing further ahead in advanced aerospace manufacturing.
Driving Innovation Through Strategic Partnerships
This isn’t just a tech project—it’s a story about collaboration fueling innovation. Renishaw, IMR, and mBryonics are pooling their expertise to tackle tough challenges in aerospace and satellite optics.
Ireland, with its strong aerospace and manufacturing roots, stands to gain a lot here. It’s shaping up to be a serious hub for advanced satellite optics production, and I’m curious to see where this leads.
Why This Matters for Aerospace Innovation
The aerospace industry leans hard on disruptive tech to keep up with the demands of modern communication systems. Satellite optics, for one, need solutions that are both reliable and cost-effective.
The Renishaw-IMR partnership points toward a future where additive manufacturing makes production smoother and less expensive. This could mean more dependable components for crucial aerospace applications.
By 2026, they hope to move from small-scale runs to full-on industrial manufacturing. If that happens, it might just shake up the standards for satellite communications and spark some fresh opportunities.
Here is the source article for this story: Renishaw and IMR advance aerospace optics manufacturing