Aerospace pertains to the navigation activities of aircraft in the solar system beyond the Karman line. It reflects the ability of human access to space as well as the exploration, utilization, and governance of the latter. Thus, space frontier leadership and industrial initiatives are demonstrated. Space equipment has become a primary factor that determines space capabilities and strategic support for national development. Motivated by space activities, such as near-Earth to deep-space and single to multiple missions, researchers are attempting to develop precise, miniaturized, and high-performance space equipment by further improving space components. The production of aerospace components presents severe challenges, such as difficulty in manufacturing complex structures and processing high-performance materials.

Additive-manufacturing technology is advantageous for manufacturing high-performance materials as well as complex and custom-designed structures, thus providing a solution for the high-quality manufacturing of advanced aerospace components. Simultaneously, the high flexibility of additive manufacturing is suitable for the evolving varieties and small quantities of aerospace components. Additive manufacturing has become a key technology in the transformation and upgradation of the aerospace industry. Based on the heat-source type, additive-manufacturing technology can be classified into arc, electron-beam, and laser additive manufacturing. The light-spot diameter of arc additive manufacturing is in the millimeter scale, which yields a high deposition efficiency but a low forming accuracy (approximately 100 μm). In electron-beam additive manufacturing, the spot radius is 100 μm, the deposition efficiency is lower than that of arc additive manufacturing, and the forming accuracy can be up to 0.13 μm higher. In laser additive manufacturing, the spot radius is typically tens of micrometers, the deposition efficiency is lower than that of electron-beam additive manufacturing, and the forming accuracy is high, i.e., up to 0.02 μm. Furthermore, it offers accurate energy control and requires a small heat input. Laser additive manufacturing is particularly suitable for the precise formation of complex aerospace components and is the most widely adopted approach in the aerospace field.

The engineering-application degree of laser additive manufacturing in the aerospace field is determined by the process, equipment, and production line. Laser additive manufacturing guarantees the high-quality manufacturing of aerospace components. The equipment used for laser additive-manufacturing equipment determines the process and is the hardware basis for the high-quality manufacturing of aerospace components. The production line for laser additive manufacturing is a platform for promoting the high-quality production of aerospace components. Owing to demands in the aerospace field, the technology, equipment, and production lines associated with laser additive manufacturing are developing rapidly. The progress of laser additive manufacturing in the aerospace industry must be summarized to guide the further application of laser additive-manufacturing technology and ultimately promote the development of aerospace laser additive manufacturing.

To accommodate complex-structure and flexible manufacturing in the aerospace field, the technology, equipment, and production lines associated with laser additive manufacturing are being tested. Based on the typical structural characteristics of aerospace components, this review describes the progress of laser additive-manufacturing technology in the high-quality formation of aerospace components. Additionally, the challenges and solutions of laser additive-manufacturing technology applications are summarized. Furthermore, guided by the aerospace demand for laser additive manufacturing, this review introduces the development status and design direction of selective-laser-melting and laser-directed energy-deposition equipment. Based on the background of the multivariate and variable batch manufacturing of aerospace components, this review describes the application of additive-manufacturing lines in high-efficiency, low-cost, and high-reliability manufacturing. Additionally, the application of laser additive manufacturing in the aerospace field is introduced and analyzed in terms of technology, equipment, and intelligent production lines. Subsequently, the development prospects of laser additive manufacturing are forecast, with emphasis on its application in the aerospace field.

The vigorous development of China space industry has promoted the development of high-performance, multifunctional, and large-scale components. The capacity of laser additive manufacturing should be further investigated to provide continuous support to the space industry. Additionally, the synergy among the technology, equipment, and production line associated with laser additive manufacturing should be strengthened to promote the application of laser additive manufacturing in the aerospace field. Additionally, the composition design of high-temperature materials and advanced structures dedicated to laser additive manufacturing can be performed. Furthermore, high-end equipment incorporating key technologies (e.g., for ensuring the stability of large-format wind fields, the reliability of optical system, and the control accuracy of the motion system) of large-scale laser additive-manufacturing equipment and flight printing can be designed. Finally, deep learning, digital twins, and artificial intelligence can be applied to production line of laser additive manufacturing.