Case Study: Senior Aerospace BWT achieves lighter, lower-cost aerospace parts with Stratasys FDM 3D printing

Senior Aerospace BWT saves up to 75% with Stratasys FDM 3D printing

Senior Aerospace BWT, a UK-based manufacturer of aerospace air distribution systems, investigated additive manufacturing to produce lighter weight components and reduce costs and lead times compared to traditional aluminum parts. They partnered with Stratasys to explore the viability of using FDM 3D printing technology with aerospace-grade materials like ULTEM 9085 resin for flight-ready parts.

The solution implemented with Stratasys involved installing two Fortus 450mc 3D printers to bring production in-house. This allowed Senior Aerospace BWT to achieve AS9100 accreditation and produce certifiable aircraft sub-assemblies. The results were significant, with Stratasys FDM additive manufacturing delivering up to 75% cost savings and substantial reductions in component weight and lead time, enabling the company to efficiently fulfill small-quantity orders.

Senior Aerospace BWT