Industries
Aerospace additive manufacturing suppliers in the UK: what to check before you order
Choose an aerospace additive manufacturing supplier by matching its approvals to the part. For prototypes, test hardware, tooling and non-flight-critical parts, a UK plastics additive supplier can deliver in days with build records. For parts that fly, you need a supplier approved for that scope. Use the checklist below to compare any supplier, including us.
Reviewed by HenleyPrint3D engineers4 min readUpdated
Key takeaways
- Our scope: prototypes, test hardware, tooling, fit-check models and non-flight-critical parts.
- Materials: PA12 (SLS), carbon-fibre filled FDM, ASA, ULTEM 9085 and flame-retardant PETG on request.
- Records: build record, material and process per build, inspection sheet on marked features.
- Not held: no AS9100 certificate; ISO 9001 in progress.
- Urgent FDM from one calendar day; the dispatch date is in the quote.
Suits
Aerospace engineers and buyers sourcing prototypes, ground-support hardware, ducting, brackets and UAV structures.
Worth knowing
Flight-critical parts need a supplier with the approvals your certification route requires. We supply build records to support your own qualification.
Aerospace additive supplier checklist
| Requirement | What to ask | HenleyPrint3D |
|---|---|---|
| Mass | Is the design reviewed for lattice, ribs and part consolidation? | Reviewed at design stage; SLS nylon and carbon-fibre filled FDM for stiffness per gram. Part mass on request. |
| Dimensional accuracy | Is the achievable tolerance stated before quote? | Typical FDM ±0.5%; SLA and SLS hold tighter on small features. Features you mark are inspected and reported. |
| Material identity | Is the material logged per order? | Material and process recorded per build. |
| Repeatability | Will batch two match batch one? | Machine, orientation, layer height and settings are recorded. |
| Flammability | Is evidence supplied for cabin-zone work? | ULTEM 9085 or flame-retardant PETG quoted on request, with the manufacturer datasheet. |
| Change control | Does the part map to one model revision? | Revision on the build record. |
| Confidentiality | NDA before geometry? | Mutual NDA on request. |
| Quality system | Which certificates, verified how? | Working towards ISO 9001. No AS9100 certificate. |
| Schedule | Is the date committed? | Dispatch date in the quote. |
Materials for aerospace prototypes and ground hardware
| Duty | Usual choice | Process |
|---|---|---|
| Stiff, light structure, UAV sections | Carbon-fibre filled nylon or PA12 | FDM or SLS |
| Ducting and manifolds with internal geometry | SLS PA12 (no support in the bore), or ABS | SLS or FDM |
| Exposed skins, sun and weather | ASA (UV stability, heat resistance around 100 °C) | FDM |
| Wind tunnel and aerodynamic models | Rigid resin, sanded and primed if required | SLA |
| Cabin-zone parts needing flame evidence | ULTEM 9085 or flame-retardant PETG, datasheet supplied | FDM |
| Drilling guides and assembly fixtures | ABS or nylon | FDM |
Grades and datasheets are on the FDM materials, SLS materials and SLA materials pages. The 3D printing materials guide explains how to choose by duty.
Flammability ratings and material datasheets
FAR 25.853 sets the flammability requirements for materials in US transport-category aircraft cabins, tested with vertical burn and, for some parts, heat-release and smoke tests. UL 94 (HB, V-2, V-1, V-0) is a plastics classification often used as a first-pass screen. A material datasheet rating is not approval of a printed part: your certification route specifies the testing. We supply the datasheet with the order so you can take it into that route.
Send the drawing and the duty
Give us the model, the loads, the temperature range and the quantity. We reply with process, material, price and dispatch date.
Documents supplied with the part
- Build record: machine, material, orientation, layer height and settings.
- Inspection sheet for the features you mark on the drawing.
- Material datasheet where flammability or temperature limits matter.
- Signed NDA, where requested.
- CMM measurement, scanning or test coupons, by arrangement and confirmed at quote.
The aerospace industry page explains the relevant standards (AS9100, and AS9102 first article inspection). Ask any supplier that claims AS9100 to show a current certificate, and verify it. The full supplier checklist is in how to choose an additive manufacturing supplier.
Design rules for lower mass and less rework
- Keep interface geometry (bolt pattern, faces, bores) fixed and redesign between them as ribs or lattice.
- Orient the main load path along the layers; FDM and SLS parts are weaker between layers.
- Merge brackets and clips into one part to remove fasteners.
- Print critical bores slightly undersize and finish to size.
- Use threaded inserts where a fastener is cycled.
More detail is in design for 3D printing and 3D printing tolerances. Related guides: 3D printed drone and UAV parts and defence additive manufacturing. To price a part, get an instant quote.
Frequently asked questions
Can you print flight-critical aerospace parts?
No. Our scope is prototypes, test hardware, tooling, fit-check models and non-flight-critical parts. We supply build records to support your own qualification route.
Do you hold AS9100?
No. We are working towards ISO 9001. Ask any supplier for a current certificate and verify it.
Which material is flame retardant for cabin use?
ULTEM 9085 or flame-retardant PETG, quoted on request, with the manufacturer datasheet. Say at enquiry that you need FAR 25.853 or UL 94 V-0 evidence.
What tolerance can aerospace prototypes hold?
Typical FDM accuracy is ±0.5% with a 0.3 mm minimum. SLA and SLS hold tighter on small features. We state the achievable tolerance before quoting.
How fast can you supply a replacement or test part?
From one calendar day for urgent FDM work; SLS and SLA take a few days depending on finishing. The dispatch date is in the quote.
Will you sign an NDA?
Yes. We sign a mutual NDA before you share geometry.
Get started
Talk to an engineer about your part.
Send your CAD, or describe the problem and the duty. We recommend the process, material and finish, and quote with the dispatch date up front.
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