The Impact of Additive Manufacturing on Aerospace Industry
Aerospace companies are turning to additive manufacturing (AM) to stay ahead of shifting supply chain challenges and labor shortages. From on-demand spare parts to innovations in Urban Air Mobility, 3D printing makes it easier to work with familiar materials while pushing the boundaries of what’s possible.
With AM, you can print end-use carbon fiber composites overnight—no long lead times, no expensive expedited fees. High-performance thermoplastics with excellent FST properties and CFR reinforcement offer the strength and lightweight benefits aerospace demands.
In this blog, you’ll learn:
- How AM is shaping the aerospace industry
- Ways to speed up tooling and prototyping
- How companies tackle compliance and regulations
- Advanced composite materials for in-flight use
- How automated inspections ensure strong, ready-to-use parts
What the Aerospace Industry Needs
In a highly regulated industry, aerospace manufacturers, OEMs, MRO providers, and airlines must balance safety, performance, and efficiency—all while meeting strict regulatory standards.
Lighter, Stronger, More Efficient
Aircraft have shifted from aluminum alloys to advanced composites like carbon fiber—today, a Boeing 787 is 50% composite by weight and 80% by volume. Why? Because lighter parts mean better fuel efficiency and lower CO₂ emissions.
3D-printed composite parts are taking flight, replacing traditional materials without sacrificing strength. Carbon fiber-reinforced prints using aerospace-grade materials can be as strong as 6061-T6 aluminum, but significantly lighter—helping manufacturers cut weight without compromising safety or reliability.
Advanced Materials for Aerospace
Beyond strength and low weight, aerospace materials need to be corrosion-resistant and withstand extreme temperatures. Aerospace-ready materials like Onyx FR-A, Carbon Fiber FR-A, and ULTEM™ 9085* (printable on the FX20) are built to handle the demands of flight.
Meeting Regulatory Standards
Every aircraft part must meet strict FAA or EASA requirements for strength, durability, UV exposure, fluid sensitivity, vibration, flame, smoke, and toxicity (FST). Choosing pre-qualified materials streamlines the approval process—avoiding costly redesigns and repeated testing.
FR-A materials on the Digital Forge provide lot-level traceability and meet the necessary test suite under 14 CFR 25.853 for most 3D-printable aerospace parts.
Material Traceability for Reliability
Traceable materials come with full documentation, including a Certificate of Conformance (CoC) and Certificate of Analysis (CoA), ensuring consistent quality. Onyx FR-A and Carbon Fiber FR-A, printed on the Markforged X7, are currently undergoing NCAMP qualification.
Simplifying Production with Part Consolidation
With the FX20’s large 525 x 400 x 400 mm build volume, manufacturers can replace multi-part assemblies with single, strong, lightweight components—reducing assembly time, minimizing errors, and improving efficiency.
Why Aerospace is Turning to Additive Manufacturing
Compared to traditional manufacturing, additive manufacturing (AM) offers clear advantages for aerospace companies—faster production, optimized designs, cost savings, and the ability to print parts exactly where they’re needed, reducing reliance on tooling and long supply chains.
Small-batch production with Greater Flexibility
Aerospace often requires small production runs of specialized parts. With AM, these can be produced quickly and cost-effectively, without the need for expensive fixtures and tooling.
Faster Prototyping and Production
With distributed manufacturing, critical parts can be printed on-site in days instead of waiting weeks for global shipments. Even placeholder parts can be printed immediately, keeping assembly lines moving while awaiting end-use components.
Streamlining the Supply Chain
OEMs using AM can reduce dependence on multiple suppliers, cutting down on logistical delays and supply chain risks. When a missing part can halt production for weeks, 3D printing ensures manufacturing stays agile, adaptable, and resilient.
Unlocking Complex Designs
AM allows for lightweight, high-strength parts that would be impractical with traditional manufacturing. Advanced software can automatically generate optimized structures with features like geometric infill and continuous fiber reinforcement (CFR), reducing material use while maintaining performance.
What is Continuous Fiber Reinforcement (CFR)?
CFR is a proprietary Markforged process that strengthens Fused Filament Fabrication (FFF) parts by embedding continuous fibers into the print. Unlike standard FFF printing, which relies on plastic infill, CFR replaces this with high-strength fibers laid within the part’s layers.
The result? Parts that are up to 10 times stronger than traditional FFF materials—lightweight, yet durable enough to replace aluminum components in aerospace applications. CFR parts provide exceptional stiffness and tensile strength at a much lower weight compared to metal, making them ideal for aerospace, automotive, and other high-performance industries.
Why Use CFR in Aerospace Manufacturing?
- Stronger Parts – CFR technology lets you adjust part strength dynamically, from plastic-grade to aluminum-grade, allowing for highly durable 3D-printed components.
- Longer Lifespan – With superior stiffness, strength, and wear resistance, CFR parts outperform standard FFF prints in real-world applications.
- Heat & Chemical Resistance – CFR parts withstand high temperatures in most manufacturing environments, while the short-fiber-filled filaments used in the process offer excellent chemical resistance.
The Future of Additive Manufacturing in Aerospace
As composite 3D printing gains traction in aerospace, advancements in technology continue to push boundaries. Larger build volumes, higher precision, improved surface finishes, user-friendly interfaces, and high-performance thermoplastics are unlocking new possibilities for aerospace applications.
Meet the FX20
The FX20 takes the power of The Digital Forge and Continuous Fiber Reinforcement (CFR) to an entirely new level—offering unprecedented size, speed, and capability for aerospace manufacturing.
- Unmatched Scale & Speed – The FX20 is the largest and most precise Markforged printer yet, featuring an 84L heated build chamber and a verified flat vacuum bed for superior print quality. Its turbo mode allows for rapid part production, while XL material spools reduce downtime from spool changes.
- Precision Engineering – The motion control system features closed-loop control with precision linear encoders, ensuring accuracy for complex aerospace components.
- Effortless Operation – The FX20’s large touchscreen interface, automated calibration and leveling, and real-time performance monitoring make it incredibly easy to use.
- Advanced Material Handling – The built-in material cabinet actively maintains moisture control, storing up to four XL spools to ensure print consistency.
With the FX20, aerospace manufacturers can now print larger, stronger parts faster than ever, opening new doors for innovation in flight.
Conclusion
Modern additive manufacturing (AM) platforms provide aerospace manufacturers with significant advantages over traditional production methods. By enabling in-house part fabrication, increased design flexibility, faster development cycles, reduced tooling costs, and improved supply chain control, AM is transforming the way aerospace components are made.
Advancements in continuous fiber reinforcement (CFR) and high-performance AM materials have made it easier for aerospace manufacturers to adopt strong, lightweight, and flight-ready components. With FAA/EASA-compliant materials featuring lot-level traceability, qualifying parts for flight is now more streamlined than ever.
The aerospace industry’s reliance on additively manufactured composites is set to grow in the coming years. As manufacturers continue to refine their AM expertise and qualify more parts for flight, initiatives like AM Forward will further accelerate adoption, making AM a cornerstone of modern aerospace production.