FAA Compliance
Full compliance with Federal Aviation Administration requirements for aircraft components and interior parts.
Aerospace SolutionsView All Industries
Accelerate Aerospace Developmentwith Advanced 3D Printing
Forge Labs delivers aerospace 3D printing for cabin interior components, UAV hardware, flight-line tooling, and lightweight prototype assemblies. We pair FST-rated polymers, engineering resins, and metal additive manufacturing with documented inspection and material traceability for qualification-focused builds.
Prototype Lead Time
72hrs
Cost Reduction
90%
Precision Tolerance
±0.25mm
Flight-Ready Materials
15+
Aerospace Overview
Revolutionizing Aerospace Manufacturing
Forge Labs supports aerospace teams with additive manufacturing workflows for aircraft interiors, lightweight brackets, UAV development, assembly tooling, and maintenance hardware. Our process is built around geometry optimization, material traceability, and repeatable inspection so engineers can move from design review to flight-relevant hardware without machining lead times.
Where additive creates leverage
Built for faster aerospace decisions
Forge Labs helps teams move from design validation to production-ready parts without waiting on tooling lead times. Consolidated assemblies, lighter parts, and faster revisions give engineering teams more control over schedule, cost, and performance.
Key manufacturing benefits
- Eliminate the high cost premium of producing complex aerospace geometries with advanced additive manufacturing.
- Enable rapid customization and design iteration across a comprehensive range of lightweight, high-performance materials.
- Simplify complex multi-component assemblies into single printed parts, dramatically reducing potential failure points and assembly time.
- Achieve significant weight reduction through optimized geometries and lightweight materials, leading to substantial operational cost savings.
- Enable on-demand production of spare parts and components, eliminating long lead times and inventory costs.
- Accelerate prototyping and design validation cycles from weeks to days, enabling rapid innovation and time-to-market advantages.
Quality and compliance
Traceability and compliance for aerospace qualification
From cabin interior components to production tooling, each build can be supported with material pedigree, inspection records, and documented process controls that help aerospace teams qualify printed parts with fewer surprises.
FST Rated Materials
Flame, Smoke, and Toxicity rated materials including ULTEM 9085 and Antero 800NA for aircraft interiors.
Material Traceability
Complete batch tracking and material certification for every component with full documentation chain.
Quality Assurance
Rigorous inspection protocols and quality controls meeting aerospace industry standards and tolerances.
Manufacturing Capabilities
Capabilities Engineered for Aerospace
From concept models to production-intent hardware, each workflow is tuned for the precision, repeatability, and engineering confidence that aerospace teams demand. Our capabilities span rapid prototyping with sub-millimeter accuracy, complex geometry optimization for weight reduction, and low-volume production with full material traceability — giving engineering teams the speed to iterate faster and the data to qualify parts with confidence.
Precision Aerospace Prototyping
Advanced stereolithography (SLA) and direct metal laser sintering (DMLS) technologies deliver aerospace-grade prototypes with exceptional dimensional accuracy and surface quality. SLA achieves tolerances of ±0.25% (min ±0.25 mm) for critical components, while our 59-inch build volume accommodates large assemblies in a single print. Parts feature intricate details down to 0.5mm resolution with wall thicknesses optimized for structural performance. Every prototype undergoes dimensional verification using calibrated CMM equipment to ensure compliance with aerospace engineering drawings and specifications.
SLA Tolerances
±0.25% (min ±0.25 mm)
Feature Resolution
0.5mm minimum
Maximum Build
1500 x 750 x 550mm
Layer Height
50-100 microns
Relevant technologies
Stereolithography (SLA)/Fused Deposition Modeling (FDM)/Selective Laser Sintering (SLS)/Multi-Jet Fusion (MJF)
Material options
High Temperature Resin/Accura 25/Accura Xtreme White 200/Accura ClearVue
Large-format SLA prototype mid-build on a 3D Systems ProX 950
Complex Geometries & Weight Reduction
Selective laser sintering (SLS) and DMLS enable unprecedented design freedom for aerospace applications. Create internal cooling channels, hollow structures with optimized wall thickness, and biomimetic lattice geometries that maintain structural integrity while minimizing mass. SLS parts require no support structures, allowing for complex overhangs and interlocking assemblies printed as single components. DMLS titanium and aluminum parts achieve aerospace-grade density with isotropic properties matching wrought materials. Topology optimization algorithms reduce material usage by 40-60% while maintaining critical load paths and safety factors required for flight-critical applications.
Weight Reduction
40-60% typical
Full Density
99.5%+ DMLS parts
Internal Channels
2mm minimum
Wall Thickness
0.8mm minimum SLS
Relevant technologies
Selective Laser Sintering (SLS)/Multi-Jet Fusion (MJF)/Direct Metal Laser Sintering (DMLS)/Fused Deposition Modeling (FDM)
Material options
DMLS titanium assembly with topology-optimized lattice structure
Low Volume Production
Multi Jet Fusion (MJF) and DMLS technologies excel at producing aerospace components in quantities from single prototypes to hundreds of parts without tooling investments. MJF delivers production-grade nylon parts with uniform mechanical properties throughout the build volume, while DMLS produces flight-ready metal components with full material traceability. Parts maintain consistent quality across batch runs with statistical process control monitoring. Digital inventory management eliminates obsolescence risks for legacy components, allowing on-demand production of discontinued parts decades after original manufacturing.
Batch Sizes
1-500+ parts
Lead Time
3-7 business days
Digital Part Archiving
Indefinite
Cost Savings
70-90% vs machining
Relevant technologies
Stereolithography (SLA)/Fused Deposition Modeling (FDM)/Selective Laser Sintering (SLS)/Multi-Jet Fusion (MJF)
Material options
High Temperature Resin/Accura 25/Accura Xtreme White 200/Accura ClearVue
DMLS metal production batch — flight-ready components with full traceability
Flight-Ready Materials
Comprehensive selection of certified aerospace materials with full compliance documentation. ULTEM™ 1010 and 9085 meet FAA flame, smoke, and toxicity requirements for aircraft interiors. Titanium Ti-6Al-4V (Grade 5) provides aerospace-grade strength-to-weight performance with corrosion resistance. Antero™ 800NA offers exceptional chemical resistance and high-temperature stability for engine compartment applications. All materials include certificates of conformance, material test reports, and batch traceability documentation required for aerospace applications. DMLS metals undergo powder analysis, build monitoring, and post-process heat treatment to ensure consistent metallurgical properties.
ULTEM™
FST compliant (FAA 25.853)
Titanium
AMS 4911 specification
Antero™
220°C continuous use
Traceability
Lot-to-part tracking
Relevant technologies
Selective Laser Sintering (SLS)/Multi-Jet Fusion (MJF)/Direct Metal Laser Sintering (DMLS)/Fused Deposition Modeling (FDM)
Material options
ULTEM™ 9085 air duct — FST rated for aircraft interior use
Repair & Maintenance Solutions
Fused deposition modeling (FDM) with aerospace thermoplastics enables rapid production of maintenance tools, fixtures, and non-critical replacement parts directly at MRO facilities. Large build volume (914 x 609 x 914mm) accommodates substantial tooling and assembly aids. ULTEM™ materials provide chemical resistance to hydraulic fluids, lubricants, and cleaning solvents common in maintenance environments. Custom jigs and fixtures reduce setup times and improve repeatability for complex assembly procedures. Digital part libraries eliminate long-term inventory storage while ensuring immediate availability of critical tooling components.
Material
ULTEM™ chemical resistant
Turnaround
24-48 hours typical
Custom Fixtures
Tailored to each procedure
Cost Reduction
80-95% vs machining
Relevant technologies
Selective Laser Sintering (SLS)/Multi-Jet Fusion (MJF)/Direct Metal Laser Sintering (DMLS)/Fused Deposition Modeling (FDM)
Material options
Technician removing FDM parts from a Stratasys F900 production printer
Design Validation
High-definition stereolithography provides exceptional surface quality and dimensional accuracy for fit-check prototypes and functional testing. 50-micron layer resolution captures fine surface details and sharp edges critical for aerodynamic testing and assembly validation. Clear and pigmented resins enable visual inspection of internal features and flow characteristics. Rapid iteration cycles support agile development methodologies with overnight prototype delivery. Multiple materials allow progressive validation from initial concept models through functional prototypes that simulate end-use material properties.
Layer Resolution
50-100 microns
Surface Finish
Ra 2-5 µm
Material Options
15+ resin systems
Accuracy
±0.25% dimensional
Relevant technologies
Stereolithography (SLA)/Fused Deposition Modeling (FDM)/PolyJet Matrix (PolyJet)/Selective Laser Sintering (SLS)
Material options
High Temperature Resin/Accura 25/Accura Xtreme White 200/Accura ClearVue
SLA seat prototypes for aircraft interior fit-check validation
Large-format SLA prototype mid-build on a 3D Systems ProX 950
Case Studies
Aerospace Manufacturing Outcomes
Examples focused on lightweight structures, aircraft interior hardware, and rapid iteration for aerospace development and UAV assemblies.
Case Study
Commercial Aircraft Interior Components
Produced aircraft interior brackets and enclosure hardware for a cabin retrofit project, cutting assembly weight by 40% while maintaining the flame, smoke, and toxicity requirements needed for interior qualification.
Key outcomes
40% weight reduction achieved
Full FST compliance maintained
90% cost savings vs machining
2-week delivery vs 12-week traditional
Case Study
UAV Prototype Development
Delivered UAV structural and thermal-management components in titanium DMLS and carbon-fiber-reinforced polymers so the engineering team could iterate flight hardware quickly without splitting assemblies across multiple fabrication methods.
Key outcomes
5x faster prototype iterations
60% lighter than aluminum equivalent
Complex internal cooling channels
Single-piece assemblies achieved
Material Library
Aerospace-Grade Materials
Qualified materials selected for performance, certification requirements, and repeatable production in aerospace environments.
FDM
ULTEM 1010
Aerospace grade
FST rated for aircraft interiors
- High temperature resistance
- Excellent chemical resistance
- UL94 V-0 flame rating
View Material Details
DMLS
Titanium Ti64
Aerospace grade
Aerospace grade Ti-6Al-4V
- High strength-to-weight ratio
- Corrosion resistant
- Biocompatible properties
View Material Details
DMLS
Aluminum 6061
Aerospace grade
Lightweight structural alloy
- Excellent machinability
- Good corrosion resistance
- Heat treatable
View Material Details
SLS
Nylon PA12
Aerospace grade
Chemical resistance
- Good fatigue resistance
- Low moisture absorption
- Excellent surface finish
View Material Details
FDM
Carbon Fiber Nylon
Aerospace grade
High stiffness-to-weight ratio
- Excellent dimensional stability
- ESD safe variants available
- Superior mechanical properties
View Material Details
SLS
Polycarbonate
Aerospace grade
High impact strength
- Temperature resistance
- Optical clarity options
- Flame retardant grades
View Material Details
Explore Our Complete Material Matrix
Compare certifications, mechanical properties, and application fit across our full portfolio before locking your production material stack.
Manufacturing Technologies
Proven Technologies for Aerospace
Evaluate each process by geometry freedom, material options, and throughput so you can pick the right path from prototype to production.
Selective Laser Sintering (SLS)
Build Volume340 × 340 × 600 mm (13.4 × 13.4 × 23.6 in)
Layer Height60 - 120 microns
Materials4 available
No Support StructuresCost-Effective for Complex Parts+4 more
Learn More
Direct Metal Laser Sintering (DMLS)
Build Volume380 × 284 × 380 mm (15 × 11.2 × 15 in)
Layer Height0.02 - 0.06 mm
Materials6 available
Fully Dense Metal PartsComplex Geometries+5 more
Learn More
Fused Deposition Modeling (FDM)
Build Volume914 × 609 × 914 mm (36" × 24" × 36")
Layer Height127 - 330 microns
Materials7 available
Large-Format PrintingCost-Effective Manufacturing+5 more
Learn More
Stereolithography (SLA)
Build Volume1500 × 750 × 550 mm (59 × 29.5 × 21.7 in)
Layer Height0.025 - 0.150 mm
Materials5 available
Highest DetailSmooth Finish+2 more
Learn More
Need help selecting the best process?
Our application engineers can map your requirements to the right technology, material, and finishing workflow before you commit to a build.
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Ready to Transform Your Aerospace Manufacturing?
Upload your CAD files for an instant quote or speak with our application engineers about your specific requirements.
- Instant pricing with automated manufacturability analysis
- Production workflows built for repeatable quality
- Engineering support from prototype to production
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STL, STEP, OBJ, 3MF supported
Instant pricing and manufacturability feedback
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- Manufacturing technologies
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- Engineering materials
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- Part quantities