Topology-optimized brackets
Load paths stay; the rest of the billet goes. SLM aluminum or titanium with machining on datums.
Industries
3D Printing in Aerospace Industry
3D printing creates complex, lightweight, and high-strength components for the aerospace industry. Complex geometries with internal channels and curved surfaces can be printed as one piece by 3D printing, which helps the aerospace industry to quickly produce and test new parts without the need for expensive and time-consuming tooling. Thus, we can help you cut costs and shorten turnaround times. We are experienced in offering dedicated 3D printing aerospace solutions for aircraft, drones, and rockets.
AIHFABS runs SLM metals and high-temp polymers in the same shop as finishing and inspection. Teams use it for brackets, ducts, and fixtures that need a photographed part — not a render — before the next design freeze.
- Rapid Prototyping
- Tooling and Fixtures
- Drones
- Surrogate Parts
- Igniters
- Cooling Systems
- Structural Components
- Landing Gear Enclosures
What aerospace teams send us
Most aerospace jobs here are structural or environmental parts that used to wait on a machine shop or a soft-tool run. Topology-optimized brackets, heat-resistant ducts, and assembly fixtures print in days, then go through bead blast, machining, or anodize on the same order.
We do not sell flight-certified serial production from this page. We do print development hardware, ground-support parts, and low-volume metal that you can measure against a drawing.
Typical aerospace parts
These are the geometries that show up most often in aerospace quotes.
Ducts and manifolds
Internal channels that are expensive to machine as a weldment. SLS nylon or SLM metal depending on temperature.
Heat-resistant fixtures
Shop-floor jigs that sit near ovens or autoclaves. High-temp resin or metal, finished for handling.
Lattice and cooling inserts
Open lattices and cooling holes that subtractive processes cannot reach in one setup.
From prototype development to production support
Plan each stage around the part’s function, material and inspection requirements—from the first design review to a repeatable batch.
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Design and manufacturability review
Share CAD, mating interfaces and critical dimensions. Review thin walls, support removal and machining access before selecting a production route.
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Prototype and fit validation
Use polymer fit-check models or metal prototypes to evaluate assembly, weight and access. Select test materials against the intended operating conditions.
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Finishing and functional evaluation
Specify threads, datum machining and surface treatments. Evaluate prototype performance against your test plan before releasing a batch.
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Inspection and repeat batches
Define dimensional checks, material records and sample acceptance criteria. Keep revisions consistent when moving from development parts to repeat orders.
Manufacturing capabilities and material options
Match the process, material and finish to the part’s geometry and operating conditions. Share your requirements so the quotation can include the necessary secondary operations.
Recommended Capabilities
- Selective Laser Melting
- Multi Jet Fusion
- Selective Laser Sintering
- Customizable Solutions
Recommended Materials
- Titanium Ti₆Al₄V
- Aluminum AlSi10Mg
- Aluminum 6061
- Nylon PA 6
3D Plus™ Hardware Solution
Our 3D Plus™ hardware solution offers comprehensive and accessible post-processing services. We offer more than 20 post-processing options for as-printed parts. For post-processing of 3D printed aerospace parts, we have anodizing, tumbling, polishing, powder coating, electroplating, and more!
Discover 3D Plus™ Hardware Solution3D Plus™ Software Solution
Our dedicated 3D Plus™ software solution is designed to streamline the 3D printing and post-processing ordering process. It simplifies your workflow by allowing you to select materials, choose post-processing options, receive instant price calculations, and collaborate with your team, all in one user-friendly platform.
Discover 3D Plus™ Software SolutionMaterials that show up on aerospace quotes
Open the material page for properties. The quote still picks the lot that matches the drawing.
SLM metals
Aluminum, stainless, and titanium alloys for structural prints.
SLS nylons
PA12 and glass-filled grades for ducts and fixtures.
CNC metals
Machined aluminum and steels when AM is the wrong first cut.
Design, material and inspection considerations
Lightweight brackets and mounting interfaces
Aluminum or titanium printing can follow curved load paths, while CNC machining can establish mounting faces, bores and threaded interfaces. Identify the load direction, fastener locations and accessible inspection surfaces; a lightweight shape still needs design validation.
Ducts, manifolds and internal passages
Review passage openings, powder removal access, wall thickness and leak-test requirements before choosing metal printing or a polymer prototype. Distinguish fit-check ducting from parts exposed to operating pressure or elevated temperature.
Inspection and configuration control
Provide the drawing revision, datum scheme and critical dimensions with the model. Agree material records, dimensional reporting and any outsourced testing during quotation. Flight qualification and airworthiness approval require a separate programme.
Related success stories
Jobs from the same shop. Industry tags are a hint, not a filter that hides the rest of the floor.
Aerospace FAQ
Do you print certified flight hardware?
This page is for development, ground-support, and inspectable low-volume metal. Certification sits with your quality system and the drawing — we print and finish to that spec.
Can you machine datums after SLM?
Yes. Call out datum faces and threads on the quote. Finishing and light machining run on the same order.
Which metal should we start with?
Aluminum for most brackets, stainless when corrosion or temperature is the driver, titanium when the mass budget is tight. The quote compares them on the same file.
Other industries
Calculate 3D Printing Costs for Aerospace Parts
Upload a STEP file to compare SLM, SLS, and CNC on the same part — then pick finishing and lead time.
