Unsurprisingly, the aerospace industry immediately adopted 3D printing as a key element of its value chain. The industry has always been at the forefront of major revolutions in terms of materials, manufacturing processes, safety standards, computerization, etc.
However, few companies currently specialize in 3D printing services for aerospace, primarily due to the complexity of the required infrastructure and the establishment of production and quality processes. Specifically, investing in robust industrial printers and obtaining specific sector certifications such as AS 9100:2016 is crucial.
Other key elements for producing aerospace-grade parts include working with flight-certified materials and adhering to a detailed methodology and process control to ensure repeatability and part quality.
Discover how Solaxis' specialization in industrial 3D printing can help you increase your competitiveness in the aerospace industry.
In general, industrial 3D printing offers many benefits for the aerospace industry. Here are the main ones.
At Solaxis, you will find a wide selection of materials certified according to FAA and NIAR regulations for aerospace products. With development and readily accessible technical data, these materials are ready to be integrated into your flight parts.
High-performance thermoplastics used in 3D printing enable the production of robust and lightweight parts. In aerospace, weight is a critical factor. Additive manufacturing allows for using less material to produce a part while maintaining necessary strength and performance.
Among the innovative techniques used to reduce weight are part consolidation and "honeycomb" filling. The design flexibility that 3D printing offers also allows for thinner walls while maintaining conformity and durability.
3D printing processes do not require investment in moulds.
Moreover, the ability to produce consolidated parts, which combine multiple pieces into one, significantly reduces the number of individually produced parts, decreasing production costs.
Parts can be designed to be lighter while offering excellent mechanical performance. Considering that every kilogram reduction in an aircraft's weight reduces fuel expenditure by approximately 30,000 litres per year, it's no wonder that the use of lighter parts is favoured in aerospace.
The speed of 3D printing is a game-changer, allowing for on-demand production of parts. The most striking advantage is the significant reduction in manufacturing lead times, from 6 months to just 6 weeks, compared to traditional manufacturing methods. The need for physical inventory is eliminated, as files can be digitally stored. This digital storage of parts enables computerized inventory management, thereby reducing overall inventory support costs. Thus, 3D printing makes the supply chain more efficient.
Part consolidation is a significant advantage of additive manufacturing. A typical aircraft contains tens of thousands of parts, some with complex geometries. Parts can be consolidated with one or more other pieces to form sub-assemblies. 3D printing can produce assemblies in a single step, significantly reducing the number of suppliers and production steps, thereby improving production efficiency and flow.
Today, 3D printing has become an essential technology for producing aircraft cabin parts. Here are some examples.
See how Solaxis can help you seamlessly integrate 3D printing into your production chain.
All aerospace manufacturers are bound by strict safety standards. In addition to these industry standards, each manufacturer has its own requirements. The part supplier must have a quality assurance system certified by an accredited body. The company is also asked to set up and maintain a continuous improvement process based on recognized methodologies and use a traceability system.
Solaxis's aerospace revenues represent 60 to 70% of our turnover. We have the expertise and equipment to meet all the basic requirements for this specialized production.
This certification standardizes quality management system requirements at all supply chain levels. It improves quality and performance and ensures the implementation of good working practices.
At Solaxis, several materials are certified for “flame, smoke, and toxicity”, according to the following standards: 14 CFR 25.853, BSS 7238 and 7239, and AITM 2.0007B and 3.0005. The tests that are carried out establish that these materials meet the following requirements:
Our manufacturing processes give us complete control over quality, from raw material to the ready-for-delivery product. We can provide all quality control documentation and follow precise production methodologies and specifications.
Our printers are configured expressly for aerospace production and calibrated according to a precise methodology.
In addition, our FAI (first article inspection) department issues an inspection report for each first-produced part of the batch, certifying that each sample was produced and inspected according to customer specifications. The aerospace and defence industries often request this.
At Solaxis, we have evaluated all materials relevant to aerospace production. We chose to work with ULTEM because of its great qualities, which is why several major aerospace companies certified it today.
This high-performance thermoplastic offers an excellent strength-to-weight ratio. It complies with FAR 25.853 for flame, smoke, and toxicity characteristics. Additionally, ULTEM 9085 resin filament has extensive documentation that allows us to provide full traceability, from the raw resin to the filament to the finished part.
At Solaxis, we can guarantee an optimal level of quality, fulfill production deadlines, and reduce costs to meet the aerospace market's many demands.
We can also certify that our team masters the technical and industrial requirements of the aerospace sector.
The aerospace industry is constantly evolving technologically and organizationally. The increase in production speed and the need for customization require a great capacity for adaptation.
Industrial 3D printing offers a vast opening for innovation, provides logistical advantages, and brings the flexibility of on-demand manufacturing. These advantages are particularly interesting and profitable for the aerospace sector.
Call on our experts; regardless of the scale of your aircraft production.