Case Study: Hangar One Avionics achieves 30‑minute per‑part inspection savings and improved accuracy with Markforged's Blacksmith

Hangar One Avionics Implements Blacksmith for Digitizing Part Inspection

Hangar One Avionics, a San Diego–based avionics maintenance, repair and installation provider, faced the challenge of producing custom, low‑volume parts that were slow and difficult to fabricate with traditional CNC machining. To speed production and reduce part weight, Hangar One adopted additive manufacturing and paired it with Markforged’s Blacksmith part inspection software to digitize and streamline the final inspection process.

Markforged’s Blacksmith automated in‑process and post‑print inspections, storing traceable data in the cloud to meet FAA recordkeeping requirements. Hangar One reports Blacksmith saves about 30 minutes per part (inspection review now takes only a few minutes), delivers accuracy within 3–4 thousandths of an inch—outperforming conventional tools—and enabled weight reductions by replacing aluminum with carbon‑reinforced composites (e.g., 5 lb per part), increasing helicopter payload/fuel/lifting capacity.

Hangar One Avionics

Matthew Roth

Head of Machining