GKN Aerospace has joined a major £38 million UK consortium, DECSAM, to accelerate the industrial adoption of sustainable additive manufacturing (AM) for aerospace. Led by Airbus, the four-year programme aims to make metal laser powder bed fusion (L-PBF) more cost-effective, productive, and sustainable for flight-ready components.
Funded through Innovate UK, the Aerospace Technology Institute (ATI), and the Department for Business and Trade, DECSAM unites 11 organisations across the UK AM supply chain. The consortium will develop and deploy advanced technologies like beam shaping and in-situ process monitoring. The core mission is to enhance resource efficiency, promote material reuse, and apply circular design principles to reduce waste and carbon intensity, supporting aviation’s transition to net-zero manufacturing.
“Additive manufacturing can unlock new efficiencies in aerospace,” said Jacqueline Castle, Chief Technology Officer at the ATI. “DECSAM unites a strong consortium to accelerate adoption in civil aerospace, aligning closely with the ATI’s strategy to drive future economic growth and sustainability.”
The programme is structured around four innovation pillars: Performance (new alloys and advanced modelling), Productivity (high-power lasers and closed-loop control), Scalability (a digital thread and automated factories), and Application (integrating technologies to demonstrate cost benefits). Key outputs will include flight-test demonstrators, validated recycled powder routes, and new qualification pathways.
GKN Aerospace will play a central role, leveraging its position as an engine manufacturer to integrate DECSAM’s technologies. The company will lead work on new sustainable materials, part-based simulation, and in-situ inspection to prove the cost-effectiveness of L-PBF for future engine products.
“This project strengthens our broader additive manufacturing capabilities, delivering environmental, performance, and supply chain advantages,” said Sébastien Aknouche, SVP Material Solutions at GKN Aerospace. “It enhances our UK technology base and positions us for future production growth.”
Ultimately, DECSAM addresses key barriers to wider L-PBF adoption, such as productivity gaps and fragmented quality assurance. By creating a fully connected, UK-based AM supply chain—from domestic powder supply to digital factory scale-up—the programme aims to produce repeatable, cost-competitive parts at volume. This supports a more resilient supply chain and cleaner manufacturing, with applications targeting efficient structures and next-generation hydrogen subsystems for aviation.
