Innovations and Challenges in Laser Direct Structured Mechatronic Integrated Devices for Aviation: Material Development, Component Design, and Additive Manufacturing

The aviation industry is striving to improve eco-efficiency by reducing the weight of aircraft and thus lowering CO2 emissions during operation. This paper investigates whether three-dimensional mechatronic integrated devices (3D-MIDs) can contribute to aircraft cabin weight reduction through laser direct structuring (LDS). The development of LDS-compatible materials that meet aerospace requirements and advanced manufacturing techniques should result in lighter components. The Passenger Service Unit (PSU) demonstrator is used to explore the potential of LDS-MIDs to achieve significant weight savings and ultimately improve the environmental footprint of modern aircraft.