3D Printing in Aerospace & Defense

Learn why 3D printers are key manufacturing tools in modern aviation, space, and defense.

The potential of 3D printing in aerospace & defense industry

Additive manufacturing provides a unique set of capabilities no other manufacturing technology can match.

Prototyping

Prototyping

3D printing is the fastest and most versatile way to move from digital designs to physical parts.

Self-sufficiency

Self-sufficiency

3D printers can manufacture any design using standardized materials which reduces dependency on external supply chains.

Reverse engineering

Reverse engineering

3D printers do not need retooling to start fabricating new designs which makes them very useful in reverse engineering applications.

Distributed manufacturing

Distributed manufacturing

Clusters of 3D printers can be used to build decentralized manufacturing systems that are robust against long-range strikes.

Crisis response

Crisis response

Additive manufacturing can be rapidly adapted to changing conditions and has been successfully used as a backup in crisis scenarios.

Wide range of 3D printing materials

Zortrax 3D printers are compatible with a range of high-quality printing materials from world-leading manufactures like Forward AM, Henkel/Loctite, Victrex, Nanovia or 3DXTech.

These materials can be used for basic prototyping, manufacturing of durable end-use parts, or for making high-performance components meeting strict aerospace or defense industry standards.

High-temperature
Flame retardant
Metal
Reinforced
Ceramic
Standard / Engineering
High-temperature Optocoupler
Optocoupler
Z-PEEK Explore more
Properties:
Space-grade, outgassing compliant polymer with industry leading thermal resistance.
 
High-temperature Mounting bracket
Mounting bracket
Victrex AM 200 Explore more
Properties:
PAEK polymer filament with very low anisotropy and excellent thermal and mechanical properties.
 
High-temperature AstroBio CubeSat frame
AstroBio CubeSat frame
Z-PEI 9085 Explore more
Properties:
Strong, flame retardant and outgassing compliant aerospace material.
 
Flame retardant Airflow pipe
Airflow pipe
BASF Ultrafuse PPSU Explore more
Properties:
Flame retardant high-performance polymer with EN 45545-2 railway classification.
 
Flame retardant LED lamp mounting
LED lamp mounting
BASF Ultrafuse PC/ABS FR Explore more
Properties:
Affordable railroad filament with the EN 45545-2 railway standard.
 
Metal Triangle bracket
Triangle bracket
BASF Ultrafuse 316L Explore more
Properties:
Metallic powder filament for 3D printing parts out of 316L stainless steel.
 
Metal Turbine rotor
Turbine rotor
BASF Ultrafuse 17-4 PH Explore more
Properties:
Metallic powder filament for 3D printing parts out of 17-4 precipitation hardened steel.
 
Reinforced Apoller turbine cover
Apoller turbine cover
BASF Ultrafuse PP GF30 Explore more
Properties:
Strong, highly rigid and thermally stable automotive polymer reinforced with glass fiber.
 
Reinforced Vise jaws
Vise jaws
BASF Ultrafuse PAHT CF15 Explore more
Properties:
An industrial-grade filament for automotive industry with addition of micro-carbon fibers.
 
Ceramic Exhaust mixer jet engine
Exhaust mixer jet engine
BASF Ultracur3D RG 3280 Explore more
Properties:
Extremely hard ceramic filling photopolymer resin with very high heat resistance.
 
Standard / Engineering Prototype shock absorber
Prototype shock absorber
Z-ABS Explore more
Properties:
Cost-efficient quality polymer widely adopted in multiple industries.
 
Standard / Engineering Brake pump
Brake pump
Z-NYLON Explore more
Properties:
Tough, durable material with excellent abrasion resistance.
 
Standard / Engineering PCB holder
PCB holder
Kimya ABS-ESD Explore more
Properties:
A filament that protects against electrostatic discharge for electronics applications.
 
Standard / Engineering A mounting clamp
A mounting clamp
Zortrax Henkel Loctite PRO 410 Explore more
Properties:
Precise, high-quality photopolymer resin with properties comparable to ABS.
 
They trusted Us
Bundeswehr
Canadian Army
Pratt & Whitney
NASA
ESA
Airbus
Curtiss
Quandum
Lockheed Martin
Leonardo
Halcon

How to use a 3D printing systems in:

Space

Space is an extremely challenging environment which necessitates high-performance materials that retain their properties in a wide range of temperatures.

Space-grade parts are therefore usually 3D printed on industrial machines like Zortrax Endureal which can work with thoroughly tested high-performance, polymers.

Space

Examples of using 3D printers in space industry

European Space Agency

Demonstrator Made on Zortrax Endureal 3D Printer Will Fly to Space in WISA Woodsat Mission

3D printed electrical circuit made on Zortrax Endureal will be tested onboard the WISA Woodsat CubeSat scheduled for launch towards the end of 2021.

Read More 1/2

Aviation

Flightworthy parts in aviation are usually printed on industrial machines like Zortrax Endureal out of materials that meet aerospace flammability standards like Z-PEI 9085. Such parts are usually used to rapidly fabricate aircraft interior components that need to be replaced in older vessels when an aircraft is due for mandatory maintenance.

Jigs, fixtures and custom equipment for ground support applications, on the other hand, are often printed on more affordable 3D printers like Zortrax M300 Dual using more cost-efficient materials like Z-ABS.

Aviation

Examples of using 3D printers in aviation

Airbus

Zortrax 3D Printed Industrial Prototypes

Read More 1/2

Defense

3D printers in defense industry are used for prototyping and producing end-use parts in new equipment undergoing tests in the military.

Such 3D printed equipment is often used to adapt existing weapon platforms to work with new types of armaments.

Defense

Examples of using 3D printers in defense industry

Quandum Aerospace

Quandum Aerospace Experience with Zortrax Inkspire 2 Resin 3D Printing Ecosystem

Quandum Aerospace, a Spanish company specializing in aerospace, green energy, and medical technologies tested new Zortrax resin 3D printing ecosystem.

Read More 1/2

Explore the applications of 3D printing in the aerospace and defense industries

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Mobile 3D printing systems for the defense and aerospace industries

The combination of desktop and industrial 3D printers with post-processing devices allows you to create an independent and remotely managed production system that can work in a variety of conditions, regardless of external supply chains.

FDM 3D printing system

Extrusion-based 3D printers are a perfect solution for workshops seeking to use cost-efficient 3D printing capabilities, rapid prototyping and on-the-fly design adjustments. Zortrax offers desktop and industrial 3D printers working in single or dual-extrusion technology:

Resin 3D printing system

UV LCD is a photopolymer resin 3D printing technology that works with outstanding precision and speed. Zortrax offers a complete resin 3D printing ecosystem with 3D printer and post-processing devices:

Free software

Z-SUITE 3D printing software with printing profiles for all supported materials and free Over-The-Air updates.

World-wide warranty

Covers stationary service and DIY repairs with technician online assistance

Cloud management

Time-saving system for efficient managing of your 3D printers.

Additional equipment

Fully equipped Starter Kit with necessary consumables.

Get Free Product Session

Schedule an individual teleconference session with Zortrax representative to learn how Zortrax 3D printers may improve your business.

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Proprietary 3D printing software

Z-SUITE is a powerful 3D printing software developed from the ground-up by Zortrax. 3D printable designs can be easily exported to it from CAD software like AutoCAD, Autodesk Fusion 360, or SolidWorks. Z-SUITE comes free with every Zortrax 3D printer. It is compatible with 3D printing materials offered by both Zortrax and external suppliers.

Learn more

Ready to use printing profiles

Z-SUITE comes equipped with an extensive base of thoroughly tested printing profiles for each supported material coming either from Zortrax or one of its trusted suppliers. Using those printing profiles guarantees best possible results when printing with supported materials.

Automatic scaling of metal parts

Metal 3D printing requires rescaling of the printed models to account for shrinkage happening at the post-processing stage when the printed model is turned into steel. Z-SUITE does the scaling automatically to ensure the dimensions of steel parts are exactly as specified in the part`s design.

Resin post-processing suggestions

3D printing with photopolymer resins is a process that requires cleaning and curing 3D printed parts. Z-SUITE has built-in post-processing suggestions explaining what exactly has to be done to achieve target mechanical and thermal properties in the resin 3D printed part.

inCloud 3D printing management

Zortrax inCloud is a cloud-based platform designed for remote management of available 3D printing staff and equipment.

Mass 3D printing

Printing of a single model can be simultaneously started at all Zortrax 3D printers connected with the inCloud account.

Remote 3D printing clusters management

With inCloud it is possible to remotely manage large clusters of Zortrax 3D printers. Each device in a cluster can be controlled individually even if each works in a different place.

Security

Zortrax inCloud operates using servers located in the Zortrax HQ in Poland which means users data is processed and hosted in a safe location in the European Union.

Customization

inCloud platform has been developed entirely by Zortrax which means it can be tailored to individual customers need if necessary.

Need a custom part? We can print it for you!

Go to 3D Printing Services

How aerospace and defense industry works
with Zortrax 3D printers

Learn more about implementing Zortrax 3D printing solutions from case studies done with Zortrax customers.

news 4D Printing Breakthrough Achieved in ESA-Funded Project

user-stories Prototyping Tools for Spacewalks—How Zortrax Ecosystem Works at NASA

products Zortrax Z-PEEK filament certified by European Space Agency

user-stories Quandum Aerospace Experience with Zortrax Inkspire 2 Resin 3D Printing Ecosystem

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