Case Study: Metro Aerospace achieves 4% cruise fuel savings and drag reduction with 3D Systems’ On Demand SLS manufacturing

Metro Aerospace Introduces 3D Printed Part for Fuel Efficiency in Aerospace

Metro Aerospace, a Texas minority‑owned supplier, developed patented 3D‑printed microvanes for the C‑130/L‑100 to reshape airflow around the aft cargo door and cut drag for measurable fuel savings. Their challenge was to move a highly regulated exterior aerospace component from prototype to production rapidly while meeting stringent inspections, documentation and certification requirements.

3D Systems’ On Demand Manufacturing team used Selective Laser Sintering with DuraForm® GF, qualified printers, material testing and a full FAIR to scale the parts into production. The effort delivered 18 ship sets (360 parts) in two months, produced a repeatable AS9100/ITAR‑compliant process, and validated performance—about 4% cruise fuel savings (≈25–30 gallons/hour and ~15 drag points)—enabling fast ROI and high customer satisfaction.

Metro Aerospace

Leslie Peters

President and CEO