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3D Printing for Aerospace

Providing proven tools and solutions to help aerospace companies meet the demanding challenges of a competitive and regulated industry.

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Over Twenty Years of Partnership with Aerospace 

Stratasys technologies help our aerospace customers build lighter, go faster and fly farther.

Stratasys polymer additive manufacturing technologies offer a broad selection of printers and materials to cover applications from prototyping to tooling to flight-worthy parts. For aerospace 3D printing applications, the most widely used technologies are FDM and P3. Stratasys Direct Manufacturing contract services offer the capability to supplement your production and validate new additive technologies.

Benefits of 3D Printing for Aerospace 

  • Cost savings: Additive manufacturing is more cost effective at low to medium volumes of production. This can lower procurement costs without sacrificing quality. 
  • On-demand manufacturing: Print parts when you need them for optimal production efficiency and supply chain resilience 
  • Accelerate prototyping and testing cycles: 3D print aerospace prototypes to reduce lead times from weeks to days or hours 
  • Weight reduction: 3D printing with durable, high-performance thermoplastics can be used to lower the weight of aerospace parts. (Aside from the inherent lower weight of plastic, partial infill and precise design of complex geometries can both also significantly lower weight.) 
  • Durability: Flight-grade 3D printing materials are available, which are uniquely suited to aerospace applications, thanks to very high strength-to-weight ratios and FST ratings, for example. 

Applications

3D printing offers time and cost efficiencies over traditional manufacturing. It lets you validate ideas quickly and speed decision making. Versatile materials provide a more effective way to make tooling and the capability to make complex flight parts lighter, with fewer components.

Prototype

Prototyping

Solve design challenges before committing to expensive and time-consuming tooling and production.

Tooling

Tooling

Avoid the high cost and long lead time of machined tools with 3D printed jigs, fixtures and custom manufacturing aids.

Applications

Flight Parts

Create complex geometries not possible with other manufacturing methods to reduce weight and consolidate assemblies.

Prototype

Prototyping

Solve design challenges before committing to expensive and time-consuming tooling and production.

Tooling

Tooling

Avoid the high cost and long lead time of machined tools with 3D printed jigs, fixtures and custom manufacturing aids.

Applications

Flight Parts

Create complex geometries not possible with other manufacturing methods to reduce weight and consolidate assemblies.

Aerospace Printers

All Aerospace Printers

Stratasys 3D printers used in aerospace applications generally include FDM and P3 DLP printers that offer a versatile range of materials comprising durable and high-performance thermoplastics and photopolymers.

F170 with part

F170 FDM Printer

Compact, dependable, entry-level professional-grade printer for accurate, repeatable 3D printing. Form factor and ease of use make it suitable for the classroom or office.

F370 with part

F370 FDM Printer

Accessible, industrial-grade 3D printer. Combines fast and easy material swaps, a generous build volume, and dependable print results to provide accurate, repeatable prototypes to production parts. Suitable for the office or factory floor.

F190CR Front

F190CR FDM Printer

A compact printer compatible with carbon fiber and engineering-grade thermoplastics to produce strong prototypes, jigs and fixtures, tooling, and parts from the classroom to the office to the factory floor.

F370CR 3D Printer

F370CR FDM Printer

A professional, industrial-grade printer compatible with carbon fiber and engineering-grade thermoplastics to produce functional prototypes, strong workholding fixtures, tooling, and parts in the office or classroom.

F770

F770® FDM Printers

The F770® industrial 3D printer provides large-format FDM® printing, making it cost-effective to produce sizable aerospace parts.

Fortus450mc

Fortus® 450mc FDM Printer

The Fortus® 450mc printer provides industrial-grade 3D printing with a wide range of materials, suitable for demanding aerospace applications.

f900

F900® FDM Printer

The F900® offers very large build capacity, high-performance materials, and exceptional reliability, making it the go-to solution for aerospace manufacturing.

orginone

Origin® DLP P3 Printer

High throughput, accuracy, and exceptional surface finishes – well-suited for components in aerospace applications.

F170 with part

F170 FDM Printer

Compact, dependable, entry-level professional-grade printer for accurate, repeatable 3D printing. Form factor and ease of use make it suitable for the classroom or office.

F370 with part

F370 FDM Printer

Accessible, industrial-grade 3D printer. Combines fast and easy material swaps, a generous build volume, and dependable print results to provide accurate, repeatable prototypes to production parts. Suitable for the office or factory floor.

F190CR Front

F190CR FDM Printer

A compact printer compatible with carbon fiber and engineering-grade thermoplastics to produce strong prototypes, jigs and fixtures, tooling, and parts from the classroom to the office to the factory floor.

F370CR 3D Printer

F370CR FDM Printer

A professional, industrial-grade printer compatible with carbon fiber and engineering-grade thermoplastics to produce functional prototypes, strong workholding fixtures, tooling, and parts in the office or classroom.

F770

F770® FDM Printers

The F770® industrial 3D printer provides large-format FDM® printing, making it cost-effective to produce sizable aerospace parts.

Fortus450mc

Fortus® 450mc FDM Printer

The Fortus® 450mc printer provides industrial-grade 3D printing with a wide range of materials, suitable for demanding aerospace applications.

f900

F900® FDM Printer

The F900® offers very large build capacity, high-performance materials, and exceptional reliability, making it the go-to solution for aerospace manufacturing.

orginone

Origin® DLP P3 Printer

High throughput, accuracy, and exceptional surface finishes – well-suited for components in aerospace applications.

Talk to our team

Questions? Talk to one of our experts today

Materials

All Materials

Stratasys 3D printing technologies offer a comprehensive material portfolio to address virtually any polymer additive manufacturing aerospace application. High-performance thermoplastics and photopolymers provide the right physical, mechanical, chemical and thermal properties needed for demanding applications in a regulated industry.

MATL

FDM Thermoplastics

P3

P3 Photopolymers

FAQ

Aerospace 3D printing uses advanced polymers to produce flight-certified components, tools, and prototypes. It supports faster development, weight reduction, and cost efficiency across the product lifecycle.

It’s applied in: 

  • Prototyping: For design validation and iteration 
  • Tooling: Jigs, fixtures, and assembly aids 
  • Production: Certified interior and structural parts 
  • MRO: Rapid, on-demand spares for aircraft maintenance 
  • Faster lead times – days instead of weeks 
  • Lower part weight – contributing to fuel savings 
  • Tool-free production – ideal for low-volume, high-mix parts 
  • Compliance-ready materials – with FST and mechanical certifications 
  • FDM®: Fortus® 450mc, F900® – ideal for durable, certifiable thermoplastic parts 
  • P3™ DLP: The Origin® platform delivers high-accuracy components with excellent surface finish using Loctite® resins 

Flight-grade materials include: 

  • ULTEM™ 9085 and Antero® 840CN03 (FDM) 
  • Carbon-fiber filled nylons 
  • Loctite® photopolymers (P3 DLP) 
    These meet aerospace mechanical, thermal, and flammability standards. 

Design iterations and prototypes can be printed in hours or days. 3D printing also helps shorten the path to part certification, reducing lead times compared to traditional manufacturing methods. 

With continual advances in material science and certification workflows, additive manufacturing is expanding to cover more critical applications, from structural airframe parts to cabin systems and unmanned platforms.