Case Study: GKN Aerospace achieves 70% faster tool lead-times and reduced production downtime with Stratasys 3D printing

GKN Driveline Overcomes Production Downtimes with 3D Printed Manufacturing Tools

GKN Aerospace (GKN Driveline Florence) faced persistent production bottlenecks caused by long outsourced tool lead-times and costly downtime—outsourcing typically required two to three weeks, delaying feasibility analyses and slowing half-shaft production. To accelerate iteration and enable more complex, bespoke tooling, the team turned to Stratasys, deploying a Fortus 450mc 3D printer and FDM engineering materials such as ULTEM 9085.

Using Stratasys FDM technology, GKN redesigned a greasing nozzle with internal valves and began 3D printing replacement brackets and bespoke end-of-arm tools on-demand. The Stratasys solution cut lead-time for the greasing nozzle by 70%, produced parts that matched metal performance to prevent downtime, and helped replace a cumbersome process with an unmanned workflow that saved two months—significantly improving responsiveness and keeping the production line operational.

GKN Aerospace

Carlo Cavallini

Additive Lead Process Engineer and Team Leader