This collaboration is part of a Disruptive Technology Innovation Fund (DTIF) project led by mBryonics, a leading manufacturer of freeform optics for the space industry.

Through the placement of a Renishaw RenAM 500Q Flex system at IMR’s facility near Dublin, researchers are developing advanced process parameters for metal 3D printing of freeform optical components used in laser-based satellite communications. By shifting from conventional machining – where parts are cut from large metal blocks – to near-net-shape AM, the project aims to improve production speed and efficiency.

The RenAM 500Q Flex, equipped with Renishaw's TEMPUS technology, was selected for this project due to its ability to overcome the specific challenges of printing highly temperature-sensitive aerospace materials. Traditional laser powder bed fusion (LPBF) systems often struggle with thermal fluctuations, which can lead to defects such as cracking. The 500Q Flex’s four-laser configuration and enhanced process control enable faster layer completion, while minimising temperature variations.

"Our approach will improve build quality and enable scalability," explained Colin Meade, Additive Manufacturing Technologist at IMR. "This research isn’t just about lab-based experimentation; it’s about developing technology that is ready for full-scale production as quickly as possible. We need to reach a technology readiness level (TRL) of around seven or higher to ensure rapid transfer to industry."

Looking ahead to the project's ambitious completion target of autumn 2026, Meade added, “In practice, this research could enable mBryonics to scale production from single-digit units per month to hundreds or even thousands.”

The partnership reinforces the importance of collaboration between industry leaders and research institutions in advancing Ireland’s aerospace manufacturing sector. Combining IMR’s expertise in advanced manufacturing research, Renishaw’s cutting-edge AM technology and mBryonics’ leadership in freeform optics, the project is set to deliver transformative results.

"Our collaboration with IMR is about more than just supplying technology, it’s about providing the expertise and support needed to drive innovation," said Chris Dimery, AM Business Manager (EMEA) at Renishaw. "By working closely with IMR, we’re ensuring that advanced additive manufacturing solutions are developed with real-world industrial adoption in mind."

www.renishaw.com/en/renam-500-flex