Industry: Aerospace · Aviation Engineering
Technology: Fused Filament Fabrication (FFF)
Application: Lightweight structural components · Rapid prototyping · Tooling · Spare parts production

Overview: Transforming Aerospace with High-Performance Polymers

With growing pressure to cut emissions and enhance efficiency, aerospace companies are turning to FFF 3D printing to manufacture lightweight, durable components. 3DGence collaborates with leading aviation firms to deliver end-use parts and functional prototypes using certified thermoplastics like ULTEM™ 9085 and PEEK, which rival metal in strength and safety.

The Challenge: Weight, Emissions & Manufacturing Complexity

Carbon Emissions – Traditional materials and processes add significant weight and increase fuel usage
High Costs – Conventional manufacturing requires costly tooling, storage, and logistics
Slow Prototyping – Design iterations are delayed due to outsourcing and rigid processes
Safety Standards – Components must meet strict flame-retardant and mechanical safety benchmarks

The Solution: FFF 3D Printing with 3DGence INDUSTRY F421

By leveraging industrial FFF printers and high-performance filaments, aerospace firms can produce parts that are:

• Up to 60% lighter than metal equivalents
• Flame-retardant and chemical-resistant
• Suitable for high-temperature and high-stress environments

3DGence’s INDUSTRY F421 features a heated chamber, precision printing, and compatibility with certified materials like ULTEM™ and PEEK. When paired with the Material Management System™ (MMS), the platform ensures full control over material prep, annealing, and traceability.

Key Benefits:

Weight Reduction – Lighter parts improve fuel efficiency and reduce emissions
Faster Prototyping – Engineers move from concept to testable part in days
On-Demand Manufacturing – Print spare parts when needed, eliminating storage costs
Design Flexibility – Complex geometries and rapid design changes supported
Certified Safety – Materials meet aerospace-grade compliance like AS9100

Use Case Highlights:

Functional Parts – Printed brackets, ducts, housings, and connectors for flight and ground equipment
Iteration Efficiency – Engineers quickly tested and updated designs during development cycles
High Fidelity – Achieved tolerances up to 0.1 mm for performance-critical features
Tooling on Demand – Jigs and fixtures printed in-house to support MRO operations

Conclusion: Scalable Innovation for the Skies

FFF 3D printing empowers aerospace manufacturers to meet sustainability goals while boosting production agility. With 3DGence’s industrial ecosystem, companies are cutting weight, costs, and lead times—without compromising safety or quality. Additive manufacturing is no longer a trend—it’s a cornerstone of modern aerospace.