Framework for Additive Manufacturing Material Readiness Levels in Aerospace Applications

Technology Readiness Levels (TRL) and Manufacturing Readiness Levels (MRL) are widely accepted frameworks for evaluating the maturity of systems and manufacturing processes. However, both assume the materials used are already mature and suitable for production. As additive manufacturing (AM) becomes increasingly integrated into critical aerospace systems, there remains no standardized method for assessing the maturity of AM-specific materials, particularly novel and new metal alloys. These alloys are continually being developed to meet aerospace demands for higher performance, including reduced weight, increased operating temperatures, and improved strength, fatigue, and creep resistance. This presentation proposes the Additive Material Readiness Level (AMRL) framework—a structured, quantitative approach for assessing the maturity of additively manufactured alloys. AMRL defines a series of developmental gates a material must pass to progress toward full system integration and production. The framework accounts for end-use requirements and includes evaluation of feedstock properties, build parameters, post-processing steps, material testing and characterization, and component-level demonstrations. The AMRL provides a clear methodology for assessing both new and existing AM alloys and supports informed decisions during conceptual design, development, and qualification phases. Case studies are presented to illustrate application of the framework and highlight common challenges and lessons learned. This research aims to establish a universal approach for qualifying AM alloys for aerospace use, ensuring materials are properly vetted before critical application.