3D Printing in Aerospace: Certification of Aircraft Interior Parts

There is a significant challenge in the aerospace industry regarding the certification of 3D-printed parts in aircraft. Until recently, every end-use component produced through additive manufacturing, no matter the technique used, had to be individually certified. For example, to manufacture a fleet of 100 aircraft containing each a 3D-printed part, each 3D component would need to go through its separate qualification process, meaning 100 separate approvals.

The fact is that, even if the part is not flight-critical, the FAA still requires strict documentation and inspections before any component can be used on an aircraft. The extensive and time-consuming qualification process made it financially unsustainable, if not entirely impractical, to use 3D-printed parts. But this era is now over. Learn about the revolutionary and simplified method to certify 3D-printed aircraft interior parts.

• A Revolutionary Certification Structure for Aircraft Interiors
• Providing Reliable Equipment and Methodology
• Certified Materials for Aircraft Interior Parts
• Providing QA and Relevant Documentation
• A Simplified Certification Process

The Revolutionary Aircraft Interior Solution 

The certification process takes a lot of time and preparation. Depending on the type of part, the aircraft manufacturer must meet various requirements and follow specific regulations. Additionally, they must ensure that all necessary documentation is provided to comply with industry standards and regulatory guidelines. Thankfully, with the Aircraft Interior Solution powered by our seven Stratasys F900 3D printers, we can follow a methodology that makes the certification process straightforward for our customers.

In partnership with the National Center for Advanced Materials Performance (NCAMP), Stratasys (our supplier of 3D printing equipment and materials) has developed an FAA-recognized certification structure that enables the reproduction of a part after qualifying just one unit. This allows aircraft component manufacturers to streamline production and reduce costs when using 3D-printed parts that are not critical to flight safety.

In the certification process for non-flight-critical parts produced through additive manufacturing, we use materials, software, and production systems that enable us to meet FAA standards consistently. This is precisely what the upgrade of our systems with the Aircraft Interiors Solution allows us to achieve.

In short, the Aircraft Interiors Solution transforms a fleet of Stratasys printers into a certifiable mini aerospace production line, with locked settings, qualified materials, and full traceability, enabling the direct manufacture of flight-ready aircraft cabin parts.

Providing Reliable Equipment and Methodology

The software motion control system of our F900 3D printers has been upgraded to ensure consistent build results, essential for demonstrating equivalency to the design allowable dataset for ULTEM 9085 resin.

Furthermore, our upgraded 3D printers offer improved material properties compared to the original configuration, maximizing the potential of materials intended for aircraft manufacturing.

The upgraded printers and the Process Control Document, which outlines the procedures for verifying correct system functionality before conducting equivalency tests, make using 3D printed parts a reliable and practical solution.

Certified Materials for Aircraft Interior Parts

The industrial 3D manufacturer must work with materials recognized by the National Institute for Aviation Research (NIAR) and recommended by the Federal Aviation Administration (FAA). At Solaxis, we use materials certified for “flame, smoke and toxicity”, according to the standards: 14 CFR 25.853, BSS 7238 and 7239, and AITM 2.0007B and 3.0005.

With the Aircraft Interior Solution, we can use certified-grade ULTEM 9085. The term “certified” means that the quality management system overseeing the production of the material, which follows a defined specification and controlled processes, has been thoroughly audited and officially approved by the FAA.

Certified ULTEM 9085 filament is manufactured in smaller quantities than standard ULTEM 9085, undergoes more frequent testing, and comes with comprehensive documentation. Any changes in resin batches necessitate a full cleaning of the extrusion equipment to ensure clear lot identification and traceability and prevent cross-contamination between different material batches.

Providing QA and Relevant Documentation

In order to provide repeatable, traceable parts that can pass FAA certification, the industrial 3D printing expert must own the kind of necessary infrastructure, and control the production and quality processes. Throughout its years of involvement in the aerospace industry, Solaxis has invested in robust industrial printers and has obtained key sector-specific certifications, such as AS 9100:2016.

It also is of critical importance that the parts supplier put in place a quality assurance (QA) system and implement and maintain a continuous improvement process based on recognized methodologies.

From its humble beginnings, Solaxis targeted the market of the aerospace industry to create a synergy between industrial 3D printing and aircraft manufacturing. Over time, we have implemented the Aircraft Interiors Solution and developed extensive expertise in this industry.

With this solution, Solaxis can provide complete and well-organized documentation that proves the quality of the equipment, the consistency of the production processes, and the traceability of material used. This helps aircraft manufacturers to speed up the certification process. The burden of qualification remains imparted to them but, at least, the printed part manufacturing is covered and simplified, and they can count on our support throughout the entire process.

A Simplified Certification Process

At Solaxis we understand the challenges faced by aircraft builders. We strive to do everything possible to facilitate the production of aircraft, and the certification of the parts we produce. The Aircraft Interior Solution establishes a straightforward process for part certification, eliminating the need for suppliers to develop their own design allowables. Instead, they only need to demonstrate equivalency to a significantly smaller test lot. With our solution, aircraft manufacturers can count on a faster way to integrate 3D printed parts in their designs, thus saving time and money.

Contact us to find out how we can help you manufacture 3D aircraft parts.