Case Study: Senior Aerospace BWT achieves certifiable, lightweight flight‑ready aircraft parts and up to 75% cost savings with Stratasys FDM 3D printing

How industry leading Senior Aerospace utilizes FDM additive manufacturing to take flight

Senior Aerospace BWT, part of Senior plc, is an AS/EN/JISQ 9100:2016‑accredited global manufacturer of ultra‑lightweight, low‑pressure air distribution systems serving regional, military, private jet and rotorcraft markets. Facing the challenge of producing flight‑ready, low‑volume interior air‑duct components while cutting weight, cost and lead times and maintaining traceability, the company investigated and adopted Stratasys FDM® 3D printing (including aerospace‑grade ULTEM™ 9085 resin) as an alternative to traditionally manufactured aluminum parts.

Working with a technical partner and Tri‑Tech 3D, Senior Aerospace BWT installed two Stratasys Fortus 450mc™ printers and qualified the associated Stratasys materials and processes to achieve AS9100 accreditation. Using Stratasys FDM and ULTEM 9085 they have produced hundreds of flight‑ready parts, realized up to 75% cost savings in some cases, reduced component weight and lead times, improved batch traceability, minimized inventory by optimizing build usage, and plan further investment in additional Stratasys FDM printers.

Senior Aerospace BWT

Darren Butterworth

Chief Executive Officer