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Aerospace
3D Printing Industry

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3D Printing Aerospace Projects

Additive manufacturing offers a number of advantages in the design of aircraft parts, ground equipment, jigs & fixtures and composite layup tools.  With 3D printing, there is no cost for complexity, allowing difficult to machine parts to be 3D printed instead, much quicker and affordably in a wide range of lightweight flight-worthy thermoplastics, composites and metals.

Small Batch Customization

Additive manufacturing unlocks a number of advantages for aerospace engineers, enabling small batch customization of complex, light weight parts in very short timeframes. Complex assemblies can be now consolidated and topology optimized to reduce aircraft weight by up to 70%. By replacing a traditionally machined part with 3D printed one, it has enabled aircrafts to reduce fuel costs, air drag as well as greatly accelerate their supply chain.

Over the life of an aircraft, additive manufacturing innovations can have significant impact on both the environment and the fuel efficiency of an aircraft. By reducing an aircrafts weight by 1kg, it has the potential to reduce CO2 emissions by 1 tonne.  Large panes burn up to a gallon of fuel every second, and due the rising cost of fuel is set to compound these expenditures.  As aerospace moves towards increasing efficiency 3D printing has proven itself to be an integral solution allowing aircraft to fly greater distances whilst reducing aircraft emissions.

Forge Labs provides an end-to-end process that goes beyond manufacturing. We offer strict quality process, material tracability and certifications to consistently offer the highest reliability in the industry.

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Functional & Repeatable Parts

Forge Labs offers highly repeatable technologies capable of manufacturing in fire rated UL94 aerospace-grade materials such as ULTEM 9085, Antero 800NA, Nylon12 FR, Titanium Ti64 and Aluminum AlSi10Mg.  Together,  these certified 3D printed materials allow for lightweight aircraft interior parts to be printed for a fraction of the traditional manufacturing costs. Designers are now free to introduce more customization within the cockpit and cabin and produce better, and lighter parts much faster than before. On the shop floor, jigs, fixtures and sacrificial composite tooling can be manufactured quicker than ever using industrial grade additive manufacturing technologies such as Fused Deposition and Laser Sintering.

3D printing applications aerospace

Case Studies


3D Printing UAV Aircarft

3D Printing Jigs & Fixtures