Marshall Aerospace & Defence using 3D printing for aircraft cabin parts and ground-running equipment

Marshall Aerospace and Defence Group is using 3D printing to produce flight-ready parts and ground-running equipment for a number of its military, civil, and business aircraft. Having installed a Stratasys Fortus 450mc, Marshall has implemented several pieces of 3D printed ducting for air conditioners, holders for safety knives, and interior switches in its aircraft. The company is also using the FDM machine to replace costly aluminium ground-running equipment with polymer alternatives and print complex tooling applications. On the ground, a ducting adapter, which works to provide fresh air to cool the avionics of an aircraft, has been printed in Nylon 12 material rather than machined in aluminium. Marshall reported a significant cost saving and a total reduction in weight of 63%. Meanwhile, 3D printed drill jigs, masking templates, bonded fixtures, and composite mould tooling have all been put in the hands of engineers within 24 hours of their request. As with the ground-running equipment, Marshall is replacing metal with plastic, 3D printing with traditional manufacturing methods, and enjoying the weight, cost, and time benefits.