Case Study: Marshall Aerospace and Defence Group achieves flight‑certified lightweight parts and rapid, cost‑effective prototyping with Stratasys

Marshall Aerospace and Defence Group Soars With 3D Printing

Marshall Aerospace and Defence Group, a UK-based aerospace and defence integrator, needed faster, cheaper and more flexible ways to prototype complex parts and produce low‑volume tooling without the delays and costs of outsourcing. To boost responsiveness across its aircraft and Land Systems businesses the company evaluated additive manufacturing and adopted Stratasys FDM-based systems, including the Fortus 450mc and F370 printers and high-performance materials such as ULTEM™ 9085 and Nylon 12.

Using Stratasys printers in-house, Marshall now produces prototypes, tooling and final parts—delivering proof of concept in a day for Land Systems and bespoke tools within 24 hours at a fraction of the cost of aluminum. Stratasys-enabled parts cut a ducting component’s weight by 63%, dramatically reduced material and machining costs, minimized tool replacement and produced flight‑certifiable components (via ULTEM™ 9085) that meet EASA requirements, improving responsiveness and lowering overall production costs.

Marshall Aerospace and Defence Group

Chris Botting

Materials, Processes and Additive Manufacturing Engineer