3D printing service for aerospace and defense — lightweight, precise, production-grade.
Aerospace and defense applications require parts that are dimensionally precise, mechanically reliable, and often optimized for weight reduction. We produce jigs, fixtures, wind tunnel models, functional prototypes, and low-volume production parts in materials that meet the performance demands of aerospace environments.
Challenges we solve
How our 3D printing service supports aerospace & defense teams
Weight optimization through additive geometry
Additive manufacturing enables complex internal geometries that are impossible with subtractive methods — lattice structures, topology-optimized brackets, hollow cores with internal ribbing, and conformal cooling channels. These geometries can reduce part weight by 30–60% while maintaining or exceeding the structural performance of solid machined parts. Our engineering team can advise on lattice design and topology optimization for your specific load case.
High-strength, high-temperature materials
PC CF delivers 8.0 GPa tensile modulus with HDT 140°C — comparable to aluminum in stiffness-to-weight ratio for non-structural brackets and fixtures. MJF Nylon PA12 provides production-grade strength at 1.8 GPa with excellent fatigue resistance across thousands of load cycles. For thermal testing and heat-proximate applications, High Temp resin withstands 238°C.
Dimensional accuracy for precision assemblies
Aerospace assemblies demand tight fits — jigs that locate against machined interfaces, fixtures that hold components to ±0.2mm during bonding, and prototype housings that must mate with flight hardware. Our SLA platform delivers ±0.2mm tolerances across build volumes up to 335 × 200 × 300mm.
Low-volume, high-mix production without tooling
Defense programs and space missions often require small batches of many different part numbers — sometimes 5–50 units of each across dozens of SKUs. Injection molding would require a separate tool for each part number at $30K–$100K per tool. Our 3D printing service produces any quantity from 1 to 5,000+ parts per order with no tooling investment, making it economically viable to produce exactly what the program needs.
Materials
Materials for aerospace & defense
For structural applications requiring maximum stiffness, PC CF (carbon-fiber-reinforced polycarbonate) delivers 8.0 GPa tensile modulus — the highest in our catalog — with HDT of 140°C. For production-grade jigs, fixtures, and functional components, MJF Nylon PA12 offers 1.8 GPa tensile modulus with excellent fatigue life and consistent properties across batch runs of hundreds of parts. Nylon PA11 provides higher ductility (100 J/m impact strength vs 40 J/m for PA12) for applications requiring energy absorption. For high-precision prototypes and wind tunnel models, SLA Tough 2K delivers ±0.2mm accuracy with smooth surfaces suitable for aerodynamic testing.
Nylon PA12
MJF · Shore D 73
Strong, lightweight, chemical resistant. The standard for functional end-use parts. Excellent fatigue resistance and consistent mechanical properties.
Nylon PA11
MJF · Shore D 80
Bio-based nylon with higher elongation and impact resistance. Ideal for parts requiring ductility and flexibility.
Nylon PA12 Glass Filled
MJF · Shore D 82
40% glass-filled nylon. High stiffness and thermal stability for demanding structural applications.
PC CF
FDM · Shore D 83
Polycarbonate carbon fiber. High stiffness and heat resistance for demanding structural applications.
ASA
FDM · Shore D 78
UV and weather resistant. Ideal for outdoor applications and functional parts exposed to sunlight.
ABS-Like Resin
Industrial SLA · Shore D 79
Tough, impact resistant. Good for large functional parts, enclosures, and assemblies.
Tough 2K
SLA · Shore D 76
ABS-like toughness with SLA detail. Functional prototypes that need impact resistance.
Rigid 10K
SLA · Shore D 90
Highly glass-filled. Stiffest SLA material. For precise industrial parts under significant load.
Common parts
Parts we produce for aerospace & defense
Built in our factory
Brooklyn, NY
How it works
From file to finished part
Upload & quote
Submit files under NDA through our secure intake form. Include tolerance callouts, material requirements, and any documentation needs for your quality system.
Engineering review
File review includes printability assessment, orientation optimization for mechanical performance, and verification of critical dimensions against your engineering drawing callouts.
Production
Parts produced with locked process parameters. Batch tracking available for all orders. Material lot traceability maintained for production runs.
QA & documentation
Three-point inspection with optional dimensional inspection reporting. Material certificates of conformity available. Documentation formatted for design history file or quality system integration.
Ship
Tracked shipping with custom packaging. Packing lists and inspection records included per your documentation requirements.
FAQ
Frequently asked questions
Do you hold aerospace certifications like AS9100?
We do not currently hold AS9100 certification. We produce parts to your engineering specifications with documented quality inspection and can provide dimensional inspection reports and material documentation for your quality records. Many aerospace customers use our 3D printing service for tooling, fixtures, and prototype parts that do not require AS9100-certified sourcing.
Can you produce flight-rated or flight-qualified parts?
Our materials are not flight-certified by default. We produce prototypes, ground support equipment, tooling, and non-flight hardware. Flight qualification and certification is the responsibility of the program integrator and must be performed against your specific qualification requirements and test protocols.
What is your strongest and stiffest material?
PC CF (carbon-fiber-reinforced polycarbonate) at 8.0 GPa tensile modulus and 140°C HDT — the highest stiffness-to-weight ratio in our catalog. For comparison, MJF Nylon PA12 provides 1.8 GPa tensile modulus with better impact resistance (40 J/m).
Can you sign NDAs and handle controlled technical information?
Yes. We routinely work under NDA and can discuss specific information handling requirements with your contracts or security team. Contact us to initiate the NDA process before submitting design files.
Do you offer topology optimization or DfAM consulting?
Yes. Our design engineering service includes DfAM (Design for Additive Manufacturing) optimization, lattice lightweighting, and scan-to-CAD conversion. We can advise on build orientation, support strategy, and geometric modifications to maximize the performance of additively manufactured parts.
Can you produce replacement parts for legacy aircraft systems?
Yes. When original tooling no longer exists or lead times from legacy suppliers are unacceptable, we can produce replacement brackets, covers, clips, and fixtures from STEP or STL files. Our digital manufacturing model means no tooling investment — upload the file and we produce exactly the quantity you need.
What is your typical turnaround for aerospace prototype parts?
FDM parts ship in as fast as 1 business day. SLA prototypes in 2–3 business days. MJF production parts in 5–7 business days. For programs with fixed milestone dates, contact our team to confirm scheduling before submitting files.
Other industries we serve
Consumer Electronics
From first prototype to shelf-ready parts — built to spec, on time.
Medical & Biotech
Precision parts for medical devices, surgical tools, and lab equipment.
Architecture & Design
Presentation models, facade studies, and design prototypes — built at any scale.
Automotive
Functional prototypes, under-hood parts, and interior trim — production-grade.
Robotics & Hardware
Custom mounts, end-effectors, and sensor housings — from prototype to production.
Marketing & Entertainment
Props, installations, and display pieces — at any scale, camera-ready.
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Insights
Related reading
Design
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Plan Your Project
Tools to plan your build
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Check Transit Time
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Ready to start your aerospace & defense project?
Upload your CAD file and get a quote in minutes — or talk to our engineers about your next production run.