Case Study: Boeing achieves rapid ROI, faster prototyping and production flexibility with 3D Systems' SLS system and DuraForm materials

Boeing Sees Growing Value & Versatility in SLS System and DuraForm Materials

Boeing’s Air Vehicle Design group in Mesa, Ariz., needed faster, cheaper ways to produce prototypes and small-run parts for programs such as the AH-64D Apache Longbow. The challenge was to reduce cycle time, eliminate costly tooling and post-processing, minimize human error in development, and enable rapid customization for varied customers without large upfront tooling investments.

They adopted 3D Systems’ SLS system using DuraForm (PA) materials, moving directly from CAD to functional parts. In five months the team produced more than 400 parts, and the system paid for itself in under a year by cutting tooling costs, post-processing and man-hours. The solution enabled on-aircraft prototypes, limited-quantity production, improved supplier communication, and broader use for functional, research and production-support applications.

Boeing

Jerry Clark

Manager, Air Vehicle Configuration Design, Integration and Rapid Development Department