Case Study: Sierra Space achieves faster, more precise spacecraft tooling with Stratasys FDM 3D printing

Sierra Space cuts chuck print time by 75% with Stratasys

Sierra Space, the manufacturer of the reusable Dream Chaser® spaceplane, faced the challenge of producing thousands of unique, precision tools called "chucks" for its thermal protection system. The traditional method of hand-casting these tools from resin was extremely time-consuming and labor-intensive. To find a better solution, Sierra Space turned to Stratasys and its F900 3D printer utilizing FDM technology.

By implementing Stratasys's additive manufacturing solution, Sierra Space automated the production of the chucks. This eliminated the manual casting process and, through design optimization, reduced print time projections by 75%. The labor savings were so significant that they essentially paid for the Stratasys F900 printer. The solution also provided critical precision for flight safety and opened new applications, with about 80% of the printer's use now dedicated to other tooling and simulation projects.

Sierra Space