Case Study: TE Connectivity achieves aerospace-grade, high-accuracy scalable production of connector parts with Stratasys Origin One

How Stratasys Origin One produced end-use 3D printed electrical connectors that meet aerospace requirements

TE Connectivity, a world leader in connectors and sensors, faced a tight timeline and demanding aerospace requirements when a helicopter customer needed a never-before‑designed, production‑grade connector holder. Traditional manufacturing and filament-based 3D printing couldn’t deliver the required aerospace‑grade materials and +/-0.002 in (≈50 µm) accuracy, so TE—an early adopter of additive manufacturing—turned to Stratasys and its Origin One solution powered by Programmable PhotoPolymerization (P3) technology.

Stratasys supplied the Origin One and, in partnership with Henkel Loctite materials, enabled TE Connectivity to 3D print a flame‑retardant, high‑accuracy photopolymer that passed industry airworthiness and environmental tests. The result: thousands of production parts (including the 369 Series connector holder), consistent +/-0.002 in accuracy, build rates exceeding 10 parts per hour, and the scalability and repeatability to support volumes into the tens of thousands—delivering measurable agility and cost‑effectiveness for TE’s aerospace customers.

TE Connectivity

Mark Savage

Senior Manager, Additive Manufacturing