Aerospace & Defense 

Stratasys Support Center – Aerospace & Defense 

Over the last decade, aerospace and defense innovators have pushed 3D printing beyond the realm of prototyping into advanced tooling and production applications. Stratasys has partnered with industry leaders to develop materials and processes that are making 3D printed parts commonplace on aircraft and spacecraft -- and cementing the technology as an engineering mainstay.

  • Documentation
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      Brochures
      • Brochure - Aerospace EN
        • 25 Nov 2018
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      • About 3D Printing Brochure
        • 16 Dec 2018
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      Case Studies
      • FDM Case Study - RLM Industries Investment Casting ENApplication Customer Story
        • 22 Nov 2018
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      • Piper Aircraft Metal Forming - EN FDM Aerospace Case StudyApplication Customer Story
        • 22 Nov 2018
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      • Neptec Return From Space - FDM EN Aerospace Case Study
        • 22 Nov 2018
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        • pdf
      • SSL Rapid-Response Tooling - FDM EN Aerospace Case Study
        • 22 Nov 2018
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        • pdf
      • China Eastern Airlines High Quality Flying - FDM EN Aerospace Case StudyChina Eastern Airlines’ new additive manufacturing lab can design, 3D print and install new parts quickly while still meeting strict approval guidelines. The airline plans to expand AM to intelligent manufacturing with zero inventory, on-demand production.
        • 22 Nov 2018
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      • Old Dominion University A Self-Navigating Boat Leads To New Career - FDM EN Aerospace Case Study
        • 22 Nov 2018
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      • Lockheed Martin Deep Space With Humans on Board - FDM EN Aerospace Case Study
        • 22 Nov 2018
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      • Indaero The Next Level - FDM EN Aerospace Case Study
        • 22 Nov 2018
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      • German Aerospace Center Mission to Mars - FDM EN Aerospace Case StudyThe German Aerospace Centre’s Institute for Robotics and Mechatronics uses FDM technology to advance space exploration, including developing a prototype for a TransRoPorter, an exploration robot for unmanned flights to Mars.
        • 22 Nov 2018
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      • Moog Aircraft Insourcing Delivers Efficiency - FDM EN Aerospace Case Study
        • 22 Nov 2018
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      • Latecoere Maintaining a Competitive Edge - FDM EN Aerospace Case Study
        • 22 Nov 2018
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      • Sheppard AFB Direct Digital Manufacturing Takes Flight - FDM EN Aerospace Case Study“Because most of our projects are either one-of-a-kind or very low volume, conventional methods become very expensive,” says Mitchell Weatherly, Chief of the TDF. “Only about 10 percent of our work is for prototyping, and 90 percent is production.”
        • 22 Nov 2018
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      • Monarch Shaping Adaptability - FDM EN Aerospace Case Study
        • 22 Nov 2018
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      • DST Control An Eye for Direct Digital Manufacturing - FDM EN Aerospace Case StudyDST developed a strategy to produce its sensitive, custom parts in-house via DDM, while outsourcing the standard parts to be made via conventional processes.
        • 22 Nov 2018
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        • pdf
      • CPI Aero Precise Contours - FDM EN Aerospace Case StudyCPI Aero manufactures structural assemblies for military and commercial aircraft that must meet very close tolerances. Adding 3D printing to its tolerance inspection process saved over $28,000 to produce a set of templates.
        • 22 Nov 2018
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      • Connecticut Corsair Restoring an Historical Aircraft to Flying Condition - FDM EN Aerospace Case StudyThe Corsair was the only fighting WWII plane designed and built in Connecticut by one corporation, today’s United Technologies Corporation. In May 2005, it was declared the state aircraft by a unanimous vote of the state legislature, and today additive manufacturing technology is bringing it back to life.
        • 22 Nov 2018
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        • pdf
      • Piper Aircraft Top Flight - FDM EN Aerospace Case StudyPiper is using hydroforming to produce hundreds of aluminum structural components of the aircraft such as the inner frame, gussets, brackets, skins, etc. In the past, the company machined aluminum form tools for use in hydroforming machines.
        • 22 Nov 2018
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      • Aurora Flight Sciences Shaping The Future of Flight - FDM EN Aerospace Case StudyCase study about Aurora Flight Sciences using Stratasys technology for lightweight structures
        • 22 Nov 2018
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      • NASA 3D Printing a Space Vehicle - FDM EN Aerospace Case StudyFor its 3D-printed parts, NASA uses ABS, PCABS and polycarbonate materials. FDM, patented by Stratasys, is the only 3D-printing method that supports production-grade thermoplastics, which are lightweight but durable enough for rugged end-use parts.
        • 22 Nov 2018
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        • pdf
      • GTRE Preparing for Flight - FDM EN Aerospace Case Study“FDM technology provided the ideal solution because the supports and interior of hollow components can be easily dissolved in a water-based solution,” says Dr. Chandrasekhar.
        • 22 Nov 2018
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      • Kelly Manufacturing A Turn for the Better - FDM EN Aerospace Case StudyAchieving tight tolerances of 0.003 in. (0.0762 mm) FDM provides substantially better dimensional accuracy than the urethane casting process, and it eliminates the need for hand sanding.
        • 22 Nov 2018
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      • Rocket Crafters Its Rocket Science - FDM EN Aerospace Case StudyABS thermoplastic's high butadiene content, when compounded with additives, offers the potential to create much higher thrust and specific impulse than traditional hybrid fuels like hydroxyl-terminated polybutadiene (HTPB) and paraffin waxes. FDM Technology easily scales to any required level of production without additional skilled labor simply by the purchase of additional Fortus Systems.
        • 22 Nov 2018
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      • PolyJet Case Study - Whale Faster to Market ES
        • 19 Dec 2018
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      • PolyJet Case Study - Whale Faster to Market DE
        • 25 Nov 2018
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      • PolyJet Case Study - Whale Faster to Market FR
        • 19 Dec 2018
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      • PolyJet Case Study - Whale Faster to Market IT
        • 19 Dec 2018
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      • Aerialtronics Taking Flight - DE FDM Aerospace Case Study
        • 9 Jan 2019
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      • Aerialtronics Taking Flight - FR FDM Aerospace Case Study
        • 9 Jan 2019
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      • Aerialtronics Taking Flight - ES FDM Aerospace Case Study
        • 9 Jan 2019
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      • Aerialtronics Taking Flight - IT FDM Aerospace Case Study
        • 9 Jan 2019
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      • NASA 3D Printing a Space Vehicle - KR FDM Case StudyFor its 3D-printed parts, NASA uses ABS, PCABS and polycarbonate materials. FDM, patented by Stratasys, is the only 3D-printing method that supports production-grade thermoplastics, which are lightweight but durable enough for rugged end-use parts.
        • 9 Jan 2019
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        • pdf
      • Aerialtronics Taking Flight - EN FDM Aerospace Case StudyAerialtronics, which manufactures customizable unmanned aircraft systems (UASs), can compete on an international level thanks to the cost savings, design freedom and improved development speed gained from 3D printing.
        • 9 Jan 2019
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      Guides and Notes
      • Application Note - Gasket Plugs and SealsOld Branding
        • 16 Dec 2018
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        • 96.42 KB pdf
      • Application Guide - Wind Tunnel Testing EN
        • 13 Dec 2018
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        • 160.5 KB pdf
      • Research Guide - 3D Printing Solutions EN
        • 19 Dec 2018
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      • Application Note - Overmolding ENOld Branding
        • 19 Nov 2018
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        • 97.91 KB pdf
      • Best Practice - Antero 800NA User Guide
        • 24 Dec 2018
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        • pdf
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      Presentations
      • Aerodynamics Application- Using Objet technology for wind tunnel model fabrication
        • 19 Dec 2018
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      • Manufacturing for Space Applications - ESD PEKK
        • 17 Dec 2018
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