Case Study: Satair achieves rapid weeks-to-days tool delivery and more sustainable aircraft maintenance with Fast Radius

How we helped Satair deliver an innovative multi-process manufacturing solution that has the potential to transform the aerospace market

Satair, an Airbus services company, came to Fast Radius to shorten aircraft maintenance lead times and improve sustainability without compromising aviation safety. Faced with MROs and airlines waiting weeks for conventionally made tools, Satair wanted an on‑demand manufacturing model; Fast Radius proposed a multi‑process additive manufacturing and digital logistics approach using the Fast Radius Virtual Warehouse and HP Multi Jet Fusion 3D printing.

Fast Radius redesigned tools for additive production, combined HP Jet Fusion 580 color 3D printing and CNC processes, and leveraged a logistics partnership with UPS to manufacture, inspect, package, ship and deliver two complete tools in under 48 hours. The pilot delivered measurable benefits—GAGS tool pads achieved about a 60% mass reduction with improved strength‑to‑weight, lead times fell from weeks to days, and the Virtual Warehouse model showed potential CO2 and material savings—while Fast Radius maintained aerospace quality through rigorous production approval and control plans.

Satair

Felix Hammerschmidt

Head of Additive Manufacturing Solutions