Case Study: BAE Systems achieves reduced costs and faster lead times with Stratasys FDM 3D printing

BAE Systems reduces costs and lead times for prototyping, aircraft tooling and part production with FDM additive manufacturing

BAE Systems, a leading UK defence, security and aerospace manufacturer, faced high non‑recurring costs and long lead times for aircraft tooling and bespoke ground equipment, plus occasional supply‑chain delays that could stall production. To support its “Factory of the Future” initiative and speed time‑to‑market, BAE Systems adopted Stratasys FDM additive manufacturing, deploying multiple Stratasys F900 3D printers at its Samlesbury site.

Stratasys supplied a battery of F900 printers (installed via partner Laser Lines) running 24/7 to produce prototypes, drill and repair tools, and final production parts using engineering thermoplastics such as ASA, ABS and Nylon 12CF. The Stratasys solution cut tooling lead times and costs, bolstered production capacity, enabled lighter cockpit floor covers and colored protective collars for faster turnaround, and avoided assembly hold‑ups with temporary “space” models — delivering significantly reduced costs and faster time‑to‑market for BAE Systems.

BAE Systems

Greg Flanagan

Additive Manufacturing Operations Lead