Aerospace Additive Manufacturing
Lighter Components. Faster Iteration.
A Practical Path To Production.
Industrial 3D printing, backed by engineers who know production.
Lightweight Parts
Faster Development
Flexible Production
In aerospace, every part has to earn its place. Weight, strength, reliability, lead time, and supply-chain availability all affect how an aircraft or aerospace system performs, and what it costs.
That’s where we come in. We help aerospace manufacturers, suppliers, engineering teams, and researchers make lighter parts, iterate faster, cut tooling, and build complex components that would be tough or expensive to make any other way.
A Flexible Partner For Aerospace Programs
From Concept to Deployment
Aerospace programs tend to involve lots of design changes, low volumes, specialized geometry, and parts that need support for years. Additive can give you an efficient path from early development all the way to recurring production.
We run selective laser sintering and polymer powder bed fusion (SLS/PBF), vat photopolymerization (SLA/VPP), and material extrusion (MEX), so we can match the process and material to what your application needs, instead of forcing every project onto one technology.
Where We Can Help
Development and testing
Aerodynamic models, wind-tunnel components, fit-and-function prototypes, test fixtures, and design-validation hardware.
Drone and UAS
Lightweight housings, brackets, ducts, sensor mounts, protective components, and customized airframe hardware.
Avionics and electronics
Equipment enclosures, protective covers, cable guides, clips, mounting hardware, and sensor housings.
Airflow and routing
Ducts, vents, manifolds, fluid-routing concepts, and complex internal passages.
Manufacturing support
Assembly aids, drill guides, inspection fixtures, custom trays, handling tools, and production tooling.
Low-volume and legacy needs
Replacement parts, specialized components, bridge production, and applications where conventional tooling is difficult to justify.
The Right Process For The Application
Multiple Polymer Technologies
Not sure which process fits? That’s our job.
SLS/PBF
makes tough engineering-polymer parts and complex shapes without support structures.
SLA/VPP
is great for fine features, smooth surfaces, tooling, and specialized resins.
MEX
is fast, works with a wide range of thermoplastics, and handles manufacturing aids and larger parts.
We’ll compare your requirements and walk you through the tradeoffs before recommending a path.
Reduce Weight And Part Count
Design Freedom
With additive, you can put material where it’s doing work and take it away where it isn’t. That opens the door to lighter parts, fewer assemblies, built-in internal passages, and simpler complex geometry.
Got an assembly made from several machined or molded pieces? It might be redesigned as a single printed part, which could mean fewer fasteners, less inventory, less assembly labor, and fewer points of failure.
Engineering Opportunities
- Part consolidation and reduced assembly complexity.
- Topology and shape optimization.
- Lightweight internal structures.
- Integrated ducts, channels, guides, and mounting features.
- Reduced tooling and inventory requirements.
- Improved manufacturability for low-volume production.
Accelerate Development And Testing
Move from CAD to Hardware Faster
Aerospace development moves fast, but tooling and long supplier lead times don’t. We help your engineering team go from CAD to hardware in your hands without waiting on dedicated tooling.
You can build, test, and tweak several design configurations before you commit to a final one. That’s a big deal for drone development, experimental aircraft, test programs, custom equipment, and anything where the design keeps changing or volumes don’t justify tooling.
Support Low-Volume And Legacy Parts
Manufacture What Is Difficult to Source
Some programs need small quantities of highly specialized parts. Others have to keep aircraft and equipment flying long after the original tooling or supplier is gone.
Additive gives you a practical option for low-volume and replacement parts without paying for new molds or sitting on big inventories. Send us the existing part, a drawing, a CAD file, or a physical sample, and we’ll tell you honestly whether additive is a viable replacement path.
Engineering And Manufacturing Support
More Than a Print Service
A good aerospace part takes more than picking a material and hitting print. We look at the whole application: loads, operating temperature, chemical exposure, dimensions, surface finish, where it’s installed, how it’ll be inspected, how many you need, and the conditions it’ll see in service.
Application and manufacturability reviews
Design for additive manufacturing
Process and material selection
Prototype and first-article production
Dimensional inspection
Mechanical testing
Post-processing and surface finishing
Process documentation and traceability
Repeat production planning
Quality Matched To Your Application
Quality and Qualification
Experimental hardware, manufacturing tooling, non-flight parts, and flight applications all come with very different requirements. We’ll work with you to sort out the documentation, inspection, testing, and qualification your part actually needs.
For applications that require customer, regulatory, or program-specific approval, those requirements should be identified at the beginning of the project so the manufacturing and validation plan can be evaluated before production.