Aerospace Parts Manufacturing

Prototype and Production Aerospace Parts

Aerospace Part Sample

Aerospace Parts & Components

Production expertise is critical to many of our aerospace customers.Solid Concepts is AS9100 certified and has an expert aerospace manufacturing engineering team with critical technical knowledge. Direct Digital Manufacturing (DDM) with additive manufacturing allows for the creation of rigid, lightweight aerospace parts not achievable with other manufacturing methods.

Due to the advancements of these technologies and materials, the aerospace industry is experiencing performance improvements with superior lightweight part design from integrated structures and component consolidation.

Ideal Aerospace Technologies

Selective Laser Sintering (SLS)

SLS is an additive manufacturing method that utilizes powdered Nylon 11, Nylon 12, and PEEK materials, including some that are certified to FAR 25.853 and 29.853 standards for flame, smoke, and toxicity. Parts produced are lightweight and strong. SLS production parts are being used for a variety of end-use aerospace applications.Read more about SLS

Fused Deposition Modeling (FDM)

FDM is an additive manufacturing process that uses production thermoplastic materials to produce fully functional parts. Materials offered include ABS, PC, and ULTEM® 9085. ULTEM 9085 is certified to UL-94V0, FAR 25.853, and FAR 29.853 standards and meets OSU radiant panel peak heat release and total heat release. Read more about FDM

QuantumCast Cast Urethanes

QuantumCast utilizes a variety of Advanced Formula Polymer materials along with soft silicone tools to produce short runs of production parts. QuantumCast is ideal for situations when the quantity does not justify the cost of hard tooling or when the design is subject to change. Read more about Cast Urethane

Aerospace Parts Expertise

Aerospace Expertise And Quality From Solid Concepts

Solid Concepts is one of the only Rapid Manufacturing Service Providers with a dedicated quality department. We have 18 individuals solely dedicated to seeing that the parts we produce are only of the highest quality. We are committed to providing accurate high-quality parts and have facilities with ISO 9001 and AS9100 certifications.

  • Boeing Double Gold Supplier
  • Raytheon 3 Star Supplier
  • Northrop Grumman Platinum Award

Our consistent dedication to quality, on-time delivery and customer satisfaction has provided a number of highly sought after awards and honors. Among these recognitions are the Raytheon 3-Star Supplier Award, Honeywell SRR, Boeing Double Gold Performance Rating and Northrop Grumman Platinum Award. With 7 U.S. facilities and thirteen manufacturing technologies, Solid Concepts has the capacity, expertise and process controls to meet all your needs.

Rapid Online Quotes

With a RapidQuotes account, you’ll have access to some of the industry’s best resources and tools including:

  • Easy access to Solid Concepts’ full product offering
  • Custom select materials and finishes for prototype parts
  • RapidQuotes for many prototyping processes
  • Start and track complex prototype projects online
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Typical Applications

  • Air Flow Ducts
  • Enclosures
  • Liquid and Fuel Tanks
  • Gimbals
  • Grommets & Clips
  • Control Surfaces
  • UAV Components
  • Mounting Brackets
Aerospace Case Example

Conformal Design for SLS

Aerospace Parts Conformal Design For SLS

This duct assembly included five custom components, 15 fasteners, adhesives and multiple assembly steps prior to being redesigned for SLS production. Redesign allowed for a single SLS production part, resulting in fewer components, reduced weight, increased strength and no need for assembly. The part can now be ordered as needed without meeting production minimums or storing excess inventory.

With “no supports required”, SLS is the premiere additive manufacturing process with enough freedom of design to allow for this level of part complexity.

Aircraft Air Duct

Aerospace Parts Aircraft Air Duct

Orbis’ Flying Eye Hospital project required a complex air duct that conformed to certain curvatures. Since the duct was to be used directly on the plane, it also had to meet all FAA requirements for airflow. Solid Concepts built the air duct with Fused Deposition Modeling (FDM) utilizing the ULTEM tan material because of its FAA compliance for smoke and toxicity regulations. The completed duct was 30” x 12.08” by 17.65” and was 8130 certified.

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