Navigating Technology Readiness Levels in Additive Manufacturing

Technology Readiness Levels (TRLs) serve as a crucial metric for assessing the maturity of a technology. Originally developed by NASA in the 1970s, TRLs provide organizations with a clear roadmap from concept to deployment. At Conflux, we recognise the pivotal role TRLs play in additive manufacturing (AM), particularly in the development of our advanced heat exchangers and coolers. By leveraging TRLs, we ensure our innovations are reliable, robust, and ready to meet industry demands.

Understanding TRLs: From Concept to Deployment

TRLs are divided into nine levels, each marking a stage in the journey toward full deployment, as defined by NASA

TRLs Across Industries: A Matter of Interpretation

Different industries interpret TRLs with varying degrees of rigor. At Conflux we tailor our approach to align with industry-specific requirements and our customer’s needs. For example, the commercial aviation sector follows highly standardised TRL expectations, often demanding extensive certification processes before a technology can progress. Our ability to navigate these nuanced requirements ensures we remain adaptable and compliant across multiple sectors.

Additive Manufacturing and TRLs: Our Unique Approach

While TRLs provide a structured framework, additive manufacturing (AM) introduces unique challenges—particularly regarding material properties. Unlike conventionally manufactured materials with well-established historical data, AM materials exhibit variability due to the laser melting process of laser bed powder fusion (LBPF). At Conflux Technology, we mitigate these challenges by:

• Building a Comprehensive Material Database – We extensively test and document material properties, ensuring consistency and reliability in our components. We are continually building upon our database through our R&D team, projects and research partners.
• Implementing Rigorous Quality Control – Our processes include non-destructive testing and in-depth material characterisation, minimising deviations and maximising performance.

Large space station orbits Earth, with city lights visible below. (Source iStock)

Customer Expectations and TRL Considerations

The stringency of TRL requirements varies depending on the customer and application. For example, a heat exchanger used in an aircraft’s environmental control system has vastly different safety and performance requirements compared to one cooling oil in a race car. Lifespan expectations also influence TRL demands—motorsport components designed for a few races undergo a different development process than aircraft parts that must endure thousands of service hours.

At Conflux Technology, we ensure customer expectations are met through:

• Customized Development Processes – Each project is tailored to its intended application, optimizing performance and reliability.
• Close Collaboration – We maintain ongoing communication with customers, conducting regular design reviews to refine and enhance our solutions.

Carefully removing an AM printed part from our EOS machine. (Source Conflux)

Bridging the Gap from TRL 4 to TRL 7

Progressing from TRL 4 to TRL 7 requires significant testing and validation. This phase is critical in identifying potential failure modes and ensuring the technology performs reliably in real-world conditions.

Our approach to overcoming this challenge includes:

• Investing in Advanced Testing Equipment – We simulate operational environments to uncover weaknesses and refine designs.
• Employing a Risk-Based Approach – Using tools like Failure Mode and Effects Analysis (FMEA), we identify and prioritize potential risks, focusing our testing efforts on the most critical areas.

For many of our customers, progressing through these levels of maturity is done in-house, particularly in commercial aviation or defence where the entire system or platform is.

A Hexagon (Hex) measuring arm performing precision measurement on a engine component for quality inspection. (Source iStock)

Lessons Learned and Our Commitment to Excellence

Over the years, Conflux Technology has refined its approach by emphasizing data-driven decision-making and aligning with industry standards. Conflux is onboarding the NASA-STD-6033 standard for additive manufacturing in spaceflight hardware that will ensure our processes meet the highest quality and reliability benchmarks.

Key takeaways from our journey include:

• Data-Driven Development – We generate extensive datasets to build statistically significant material property databases, ensuring precision and repeatability.
• Adhering to Industry Standards – Compliance with established benchmarks enhances our credibility and ensures customer confidence.

Finished water charge air cooler, engineered for optimal thermal performance and durability. (Source Conflux)

Supplying Data for Certification

We prioritise transparency and provide customers with comprehensive data packages to demonstrate certification compliance. These packages can include:

• Material Property Data – Detailed mechanical property insights, such as tensile strength and elongation.
• Process Control Data – Evidence of manufacturing consistency and repeatability.

As an ISO 9001 and AS9100D certified company, Conflux Technology remains committed to maintaining the highest quality standards in everything we do.

Technology Readiness Levels provide an invaluable framework for guiding the development and deployment of additive manufacturing innovations. By embracing TRLs, addressing AM-specific challenges, and leveraging robust material databases, Conflux Technology continues to lead the way in delivering advanced thermal solutions across diverse industries. We take pride in driving innovation, exceeding customer expectations, and pushing the boundaries of what’s possible in additive manufacturing.