USA & Canada
USA & Canada

Aerospace 3D Printing Service

3D Printed Custom Manufacturing on Demand

A leader in specialized aerospace projects, delivering high-requirement parts with full traceability, capable of producing flight-worthy components that meet rigorous testing standards.

ISO9001 & AS9100 Certified | DDTC/ITAR Registered

Manufacturing Capabilities​

Aerospace Flight Pars | Stratasys Direct

Flight Worthy Parts

115,000+ Qualified flight parts shipped per year

Qualified 26 material specs, 46 process specs | Stratasys Direct

Qualified Specs

Qualified to manufacture parts to 26 material specs, 46 process specs

In-house manufacturing 3d printing | Stratasys Direct

200+ In-House Printers

U.S. based industrial additive manufacturing machines

Full-Service Inspection and Finishing  | Stratasys Direct

Full-Service

25+ Post-process production finishing and inspection services​

Aerospace Drone flying in sky | Stratasys Direct

Innovative Aerospace & Defense 3D Printing Solutions

We specialize in delivering high-quality 3D printed parts tailored for commercial aircraft, defense systems, helicopters, ordnance, drones, and more. With rigorous certifications and a commitment to precision engineering, our components are designed to meet the demanding standards of the industry. Companies have successfully utilized our parts in various flight-approved applications, showcasing our expertise and reliability. Explore our advanced solutions to enhance your aerospace and defense projects with cutting-edge technology and exceptional quality.

 

Airplane in Sunset | Quality | Stratasys Direct

Stratasys Direct® is Certified, Registered, or Compliant to:  

With Projects or Experience in:

  • DPAS - Defense Property Accountability System
  • EAR - Export Administration Regulations
  • FARS/DFAR Contracts

Flight & Space Worthy Materials

Stratasys Direct, a leader in additive manufacturing, offers an impressive suite of flight-worthy materials tailored for the aerospace industry. Stratasys Direct's commitment to quality is underscored by our qualification to manufacture flight parts, adhering to 26 material specifications and 46 process specifications.

Other materials with properties, testing, or certification may be available. Please contact us or start a quote to discuss with our aerospace experts.

 

Key Features
  • High strength to weight ratio
  • High thermal and chemical resistance
  • Leading repeatability part to part
Testing Examples
  • Chemical Exposure per ASTM D543
  • 14 CFR 25.853
  • 14 CFR 25.853, BSS 7238 and 7238, and AITM 2.0007B and 3.0005
  • Nasa low outgassing
A PEKK-based thermoplastic with the highest tensile strength offered, high chemical resistance and wear resistance. This material is FST compliant per "14 CFR 25.853" & "ASTM F814/E662". Antero 800NA is a lighter alternative to metal alloys. Available in sparse or solid fill.
Key Features
  • Exceptional chemical and wear resistance
  • Ultra-low outgassing properties
  • Consistent ESD performance
  • UV Exposure
Testing Examples
  • ANSI ESD S20.20, S11.11, STM11.12
  • Chemical exposure per ASTM D543
  • 14 CFR 25.853
  • BSS 7238
  • AITM 2.0007B, and 3.0005.
Antero 840CN03 is a carbon nanotube-filled FDM thermoplastic combining the excellent physical and mechanical qualities of PEKK with electrostatic dissipative (ESD) properties. The thermoplastic is ESD safe, high chemical resistance, ultra-low outgassing and high mechanical/thermal properties.
Key Features
  • High strength to weight ratio
  • High thermal and chemical resistance
  • Leading repeatability part to part
Testing Examples
  • UV tested per ASTM D638 & ASTM G154
  • 14 CFR 25.853, BSS 7238 and 7239, and AITM 2.0007B and 3.0005. 
  • NASA low outgassing
ULTEM™ 9085 Resin CG (certified grade) has improved mechanical properties with upwards of 39% increase to tensile strength and upwards of 65% increase to elongation at break in the Z orientation compared to standard ULTEM™ 9085 resin. FST certified per 14 CFR/FAR 25.853 & ASTM F814/E662. Available in sparse or solid fill.
Key Features
  • Polyamide composite with excellent fire retardancy
  • Passes FAR 25.853 12 Second and 30 Second Burn tests
  • Exceptional elongation at break
  • Passes FAR 25.853 Smoke Density test

Applications

  • Aerospace production parts
  • Underhood components
  • Well suited for demanding applications which require flame retardancy
Nylon 11 FR designed for use in commercial, military and civil aircraft requiring fire retardant parts. Material passes FAR 25.853 15 and 60 second vertical burn tests. Material also passes smoke and toxicity requirements. Parts exhibit excellent elongation (21% - 38%) with increased durability and greater flexibility over Nylon 12 PA parts.
Key Features
  • Material passes 60 second vertical burn test
  • Best accuracy & surface finish of available fire retardant materials
Applications
  • Aerospace applications requiring excellent mechanical strength
  • Underhood components
  • Applications requiring fire retardant properties
Nylon 12 designed for use in commercial, military and civil aircraft interiors requiring fire retardant parts. Material passes FAR 25.853 15 and 60 second vertical burn tests. Material also passes smoke and toxicity requirements. Because Nylon 12 FR has lower shrink than Nylon 11 FR, it is better suited for larger parts.

Aerospace Technologies

Stratasys Direct utilizes cutting-edge 3D printing technologies to produce high-quality aerospace parts. With 3D printing, complex geometries and intricate designs can be achieved, ensuring lightweight yet durable components.

FDM for Aerospace | Stratasys Direct

FDM® - Fused Deposition Modeling

Ideal Part Size: Small - Mid - Large

SLS for Aerospace | Stratasys Direct

SLS - Selective Laser Sintering

Ideal Part Size: Mid - Large

DLP P3 for Aerospace | Stratasys Direct

P3™ DLP - Programmable Photopolymerization

Ideal Part Size: Small

SAF for Aerospace | Stratasys Direct

SAF™ - Selective Absorption Fusion

Ideal Part Size: Small - Mid

MJF for Aerospace | Stratasys Direct

MJF - Multi Jet Fusion

Ideal Part Size: Small - Mid

SLA for Aerospace | Stratasys Direct

SLA - Stereolithography

Ideal Part Size: Mid - Large

PolyJet for Aerospace | Stratasys Direct

PolyJet™

Ideal Part Size: Small - Mid

FDM for Aerospace | Stratasys Direct

Ideal Part Size: Small - Mid - Large

SLS for Aerospace | Stratasys Direct

Ideal Part Size: Mid - Large

DLP P3 for Aerospace | Stratasys Direct

Ideal Part Size: Small

SAF for Aerospace | Stratasys Direct

Ideal Part Size: Small - Mid

MJF for Aerospace | Stratasys Direct

Ideal Part Size: Small - Mid

SLA for Aerospace | Stratasys Direct

Ideal Part Size: Mid - Large

PolyJet for Aerospace | Stratasys Direct

Ideal Part Size: Small - Mid

Airplane Commercial & Defense Applications | Stratasys Direct

Airplane Commercial & Defense Key Applications

Stratasys Direct assists in producing flight-worthy parts for both commercial and defense aircraft, including electronic cooling ducts, environmental control system ducting, wire guides, electrical connectors, and more.

Flight-worthy Parts

  • Electronic Cooling Duct
  • Defog Airduct
  • Environmental Control System Ducting
  • Filter Boxes / Connectors / Reducers
  • FOD Barriers
  • Wire Guides / Conduits
  • Electrical Connector / Wiring Blocks
  • Clips and Clamps
  • Hydraulics Supports / Stand Offs
  • Component Connectors
  • Camera / Gimbal Mount
  • Air Intake Plenum / Manifolds
  • Brackets / Covers
  • Spacer C
  • Microvanes
  • Drain Fairing
  • Gaskets
  • Plated Production Part

3D printing these parts delivered an immediate weight savings benefit. Additionally, the lower part count translated into cost savings on the administrative side including inspection, purchasing, and product support."

Remote Piloted Aircraft Applications | Stratasys Direct

Remote Piloted Aircraft / Drone Key Applications

Stratasys Direct aids in producing various components for remote piloted aircraft, including payload enclosures, conformable fuel tanks, wing structures, battery compartments, avionics enclosures, aerodynamic surfaces, and more.

Flight-worthy Parts

  • Payload Enclosures / Attachments
  • Conformable Fuel Tank
  • Shrouds and Closeouts
  • Wing Structures
  • Battery Compartment
  • Oil Tank / Glycol / Hydraulic Fluids
  • Aileron Flaps
  • Avionics and Radio Closures
  • Aerodynamic Surfaces
  • Connectors / Reducers
  • Wire ways / Conduits / Connectors
  • Clips / Clamps / Grommets
  • Hydraulics Supports and Stand Offs
  • Fuselage Components
  • Component Connectors
  • Air Filter Boxes / Air Ducting
  • External Camera and Gimbal
  • Air Intake Manifolds
  • Brackets
  • Mounting for PODS / Avionics and Electrical Systems

Additive manufacturing has completely changed the way we design aircraft... we used to shy away from certain complex designs, opting for more basic structures. Additive manufacturing has allowed us to design and build mechanisms and structures we wouldn’t be able to make with any other manufacturing method."

Satellite, Helicopter & Missile Applications | Stratasys Direct

Helicopter Satellites, & Ordinances Key Applications

Stratasys Direct supports helicopter and commercial & defense applications by offering design, engineering, and manufacturing solutions. From engineering models and fit tests to the production of fuselage components and cabin interiors, we provide a comprehensive range of services. Our expertise extends to manufacturing FOD barriers, clips, clamps, electrical connectors, and various cabin interior components, ensuring high-quality and reliable aerospace solutions.

Design & Engineering

  • Engineering Models / Fit Test
  • Assembly / Repair
  • Drill blocks / Guides
  • Router Template
  • Layup Tools / Molds / Trim Fixtures
  • Printed Tools for Bonding Structures
  • Painting / Overspray Fixture
  • Skunk Works / Model Shop

Manufacturing

  • FOD Barrier / Protection
  • Clips and Clamps
  • Electrical Connector
  • Wiring Blocks / Guides
  • Hydraulics Supports and Stand Offs
  • Fuselage Components
  • Component Connectors
  • Air Filter Boxes / ECS Ducting
  • Connectors / Reducers

 

Cabin Interior Flight Parts Applications | Stratasys Direct

Cabin Interiors / Flight Parts

  • Training Helmets High-end Military
  • Cabin Vents
  • Display Shroud / Closeouts
  • Bezels / Trim
  • Custom Cosmetic and Decorative Components
  • Camera Adaptors
  • Interior Door Latch Components
  • Storage Bin Dividers
  • Defogger Windshield and Duct Nozzles
  • Cup Holder
  • Canopy Latch Mechanism
  • External Camera and Gimbal
  • Micro Vanes
  • Air Intake Manifolds
  • Trim & Drill Guide

Ready to Innovate Your Aerospace Project with Our 3D Printing Experience & Expertise?

Start Your Custom Project

Frequently Asked Questions

Stratasys Direct is ITAR registered and carries both ISO 9001 and AS9100 certifications. Stratasys Direct can provide in-house AS-9102 FAI (First Article Inspection) services.

We are committed to Quality Assurance through delivering the best parts on the market and ensuring complete data security with every project.

Yes, we work with companies around the world often, additional information and screening may be required at the time the order is placed.

 

Our largest SLS machine has a build chamber size of 26.5” x 13.5” x 20” and our largest FDM machine has a build chamber of 36” x 24” x 36”.

Parts that exceed those dimensions can be built in sections and bonded in a variety of ways that ensure stability and strength.

In addition, bonded joints can be combined with the design of dovetail, tongue, and groove, or sometimes lap joints. 

Stratasys Direct accepts a wide variety of 3D CAD file formats. You don’t need to convert your CAD data to STL to receive a quote.

Files accepted include STL, STEP, IGES, Pro/E, CATIA, Parasolid, SolidEdge, SolidWorks, Autodesk Inventor, Unigraphics as well as files from other popular 3D CAD programs.

 

Aerospace Resources

Aerospace Resource guide for 3D Printing - Additive Manufacturing

Additive Manufacturing Solutions for Aerospace

Leveraging 30 years of experience in 3D printing for aerospace, Stratasys Direct is please to present our Aerospace AM Solutions Guide. This guide offers invaluable insights on how you can harness additive manufacturing.

View more
3D Printed Aerospace Parts | Stratasys Direct Manufacturing

3D-Printed Aerospace Parts: Bringing Behind the Scenes Parts into the Spotlight

Discover where aerospace and additive manufacturing intersect in our new whitepaper, 3D-Printed Aerospace Parts: Bringing Behind the Scenes Parts into the Spotlight.

View more
Stratasys Direct Boom supersonic Webinar details

Breaking the sound barrier with additive manufacturing

Learn how aerospace is maximizing the utilization of 3D Printing including a first-person account from Boom Supersonic, a long-time user of 3D printing technologies.

View more
Stratasys Direct Airplane touch screen on seat

3D-Printed Aerospace Parts: Bringing Behind the Scenes Parts into the Spotlight

Discover Aerospace Behind-the-Scenes 3D-Printing. Join our webinar on Aerospace Manufacturing, Post-Processing Impact, and Materials. Register Now!

View more
Economic Growth

Additive Manufacturing: Catalyzing Industries, Powering Economic Growth

Discover how additive manufacturing serves as a catalyst for economic growth and technology innovation. Read more here.

View more
Aerospace Additive Manufacturing

Taking Flight: 3D Printing Production Parts for Aircraft Interiors

Learn the diverse applications of 3D printing in aircraft interiors emphasizing the advantages, including lightweight components, on-demand manufacturing, and tool-free production.

View more
bell helicopter

Developing Flight-Ready Production Hardware with Laser Sintering

Bell Helicopter turned to us for the production of several components of ECS ducting with Laser Sintering and reaped cost savings and weight reduction.

View more
uav tanks

Conformal Fuel Tank Expands UAV Range

Advanced Ceramics Research designed a 3D printed UAV to provide low cost aerial surveillance imaging. Read how we helped in this case study.

View more
aircraft interiors

AM in Aerospace Infographic

Check out this infographic for an overview of additive manufacturing and 3D printing in aerospace including the benefits and some common applications.

View more
Aerospace Resource guide for 3D Printing - Additive Manufacturing

Leveraging 30 years of experience in 3D printing for aerospace, Stratasys Direct is please to present our Aerospace AM Solutions Guide. This guide offers invaluable insights on how you can harness additive manufacturing.

3D Printed Aerospace Parts | Stratasys Direct Manufacturing

Discover where aerospace and additive manufacturing intersect in our new whitepaper, 3D-Printed Aerospace Parts: Bringing Behind the Scenes Parts into the Spotlight.

Stratasys Direct Boom supersonic Webinar details

Learn how aerospace is maximizing the utilization of 3D Printing including a first-person account from Boom Supersonic, a long-time user of 3D printing technologies.

Stratasys Direct Airplane touch screen on seat

Discover Aerospace Behind-the-Scenes 3D-Printing. Join our webinar on Aerospace Manufacturing, Post-Processing Impact, and Materials. Register Now!

Economic Growth

Discover how additive manufacturing serves as a catalyst for economic growth and technology innovation. Read more here.

Aerospace Additive Manufacturing

Learn the diverse applications of 3D printing in aircraft interiors emphasizing the advantages, including lightweight components, on-demand manufacturing, and tool-free production.

bell helicopter

Bell Helicopter turned to us for the production of several components of ECS ducting with Laser Sintering and reaped cost savings and weight reduction.

uav tanks

Advanced Ceramics Research designed a 3D printed UAV to provide low cost aerial surveillance imaging. Read how we helped in this case study.

aircraft interiors

Check out this infographic for an overview of additive manufacturing and 3D printing in aerospace including the benefits and some common applications.

From one-off prototypes, to low-volume production, we have the experience and engineering know-how to support you

Contact Us

9085, 1010 and ULTEM™ trademarks are used under license from SABIC, its affiliate or subsidiary.