Case Study
Additive Manufacturing of Multi-Function Pitot-Static Probe
Integration of Ptot, Pstat and AoA measurement into one compact body
Project Context
A light aircraft development team needed a compact Air Data Probe that would:
- measure total pressure (Ptot)
- provide reference static pressure (Pstat)
- enable angle of attack (AoA) calculation
- be ready for operation in adverse weather conditions –40 °C to +55 °C
Traditional probe designs required more components, complex internal routing and higher weight.
Challenge
Conventional manufacturing had three fundamental limitations:
- Complex internal geometry – difficult to achieve by machining
- More joints = higher risk of leaks
- Higher assembly weight
The goal was to create a monolithic solution without design compromises.
Solution
Additively manufactured monolithic Air Data Probe
We chose industrial additive manufacturing complemented by a metal tip from aviation-grade aluminum alloy, enabling integration of all functions directly into one compact probe body.
Integrated Pitot-Static System
Internal channels as part of the structure, without additional joints. Integrated 6mm fitting for direct connection to air pressure distribution.
Angle of Attack (AoA) Measurement
Optimized tip and sampling port placement enable precise AoA calculation without a separate sensor.
Integrated Heating (Anti-icing)
The design enables direct integration of a heating element with max 4W consumption. Internal geometry is optimized for even heat transfer to critical areas, reducing the risk of ice formation.
Weight Optimization
Internal cavities and structural ribs reduce weight while maintaining stiffness and vibration resistance.
Project Results
- Integration of multiple functions into one probe body
- Reduction of component and joint count
- Weight reduction compared to traditional assembly
- Simplified aircraft installation
- Increased vibration resistance
- Cost reduction compared to traditional suppliers for general aviation and ultralight aircraft
Technical Parameters
Conclusion
Additive manufacturing enabled the creation of a multi-function Air Data probe that integrates advanced functions into one compact and structurally clean solution.
The project demonstrates that 3D printing is not just an alternative manufacturing method, but a tool for functional integration and structural optimization in aviation.