Riede, MirkoMirkoRiedeHeidowitzsch, MaximilianMaximilianHeidowitzschWerner, TorstenTorstenWernerSamuel, ConradConradSamuelLopez, ElenaElenaLopezBrückner, FrankFrankBrücknerLeyens, ChristophChristophLeyensBavdaz, MarcosMarcosBavdazNorman, AndrewAndrewNorman2025-03-182025-05-152025-03-182024-08-26https://publica.fraunhofer.de/handle/publica/48564010.1117/12.3020113The large class science mission NewATHENA, rescoped by the European Space Agency (ESA) in November 2023, will explore the hot and energetic universe using advanced X-ray technology. The key components of the telescope will be hundreds of Silicon Porous Optics (SPO) modules arranged in an optical bench with a diameter of around 2.7 metres. Considering the overall size, the delicate cell structure and the high aspect ratio in combination with the material-related challenges of Ti6Al4V, additive manufacturing using Direct Energy Deposition (DED) is a promising alternative to conventional processing. In addition to discussing fundamental challenges (e.g. shielding), the development of a highperformance hybrid DED process and associated equipment for robust long-term production will be presented. The developed end-to-end manufacturing approach will be verified by manufacturing and analysing test specimens, geometric demonstrators and representative large breadboards.enAdditive manufacturingAdvanced manufacturingLarge-scale partLaser metal depositionTi-6Al-4V600 Technik, Medizin, angewandte Wissenschaften600 Technik, Medizin, angewandte Wissenschaften::620 Ingenieurwissenschaftenconference paper