Aerospace engineering
Aerospace development parts with SLS
Polymer laser sintering for aerospace development: environmental-control duct prototypes, aerodynamic models, cabin interior development parts, tooling and fixtures. Our focus is non-flight-critical hardware for development, testing and production support.
Regulated flight applications
Parts intended for certified or regulated flight applications need qualification and approvals that go beyond manufacturing. Tell us the intended use in your request and we will be clear about what we can and cannot support.
Typical scope
- Development and test hardware
- Aerodynamic and wind-tunnel models
- Tooling, jigs and fixtures
- Ground-support and laboratory equipment parts
Requires separate qualification and approval
- Parts for installation on certified aircraft
- Flight-critical or safety-relevant components
- Parts that require formal airworthiness approval
Typical parts
Development hardware, tooling and test parts
Parts that support aerospace programs on the ground, in the lab and on the shop floor.
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Environmental-control duct prototypes
Duct runs with flanges, bends and mounting bosses in one piece, for fit checks, flow tests and installation studies.
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Cabin interior development parts
Mock-up panels, trim, brackets and housings for design reviews and ergonomic trials.
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Wind-tunnel models
Model components and inserts with internal pressure-tap channels, where the test plan allows polymer parts.
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Aerodynamic prototypes
Fairings, inlets and shape studies for early aerodynamic evaluation and design reviews.
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Assembly jigs
Lightweight jigs that hold and position parts during assembly and are easy for operators to handle.
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Drilling and inspection fixtures
Fixtures and check gauges shaped to the part, with features for drill bushings or measuring points.
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Tooling and handling aids
Masking tools, trim templates, protective covers and handling aids for production and maintenance.
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Cable routing parts
Clips, guides and brackets for harness routing in prototypes, test rigs and ground equipment.
Why SLS
Why laser sintering suits aerospace development
Development hardware changes as often as the design it supports. SLS takes tooling out of that loop and reaches geometry that machining and molding cannot.
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No support structures
Ducts, closed profiles and internal passages are built without supports, so there is nothing to remove from inaccessible areas.
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Nesting for batches
Duct segments, brackets and fixtures for one test campaign can be nested in a single build.
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Complex internal channels
Turning vanes, pressure-tap passages and integrated flanges are built into the part rather than assembled.
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Lattice lightweighting
Large jigs and fixtures can use lattice or ribbed cores, so operators handle less weight.
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Part consolidation
Duct assemblies of several segments, clamps and brackets can become one part with fewer joints to seal.
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Fast iterations without tooling
A revised duct run or fixture is a new build, not a new tool, which keeps development hardware in step with the design.
Engineering considerations
What to plan for
We review these points with you before quoting. Where a requirement is beyond our current scope, we say so.
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Fire behavior
Cabin and duct applications can carry flammability requirements, so tell us early whether your development part needs a flame-retardant material.
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Surface texture
As-sintered surfaces are matte and slightly grainy, which matters for aerodynamic and flow-test parts. Standard finishing is depowdering and bead blasting; smoothing and coating belong to extended finishing.
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Part size
Large ducts and models must fit the build envelope with margins, or be split into sections with designed joints. We plan the split with you in the review.
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Documentation
Every order we produce gets a production record. State your documentation needs with the request, and the quotation confirms what we can provide.
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Tolerances
Accuracy depends on geometry, size and build orientation. Critical dimensions and interfaces are agreed in the engineering review; we do not quote generic tolerance values.
Materials & platform
Materials for development hardware
PA 12 is our primary material. Every material is shown with its current status.
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PA 12
Primary material Status: CommissioningThe default for duct prototypes, models, jigs and fixtures, with a good balance of strength, toughness and low moisture absorption.
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PA 12 FR
Status: PlannedA flame-retardant grade for interior and duct development parts where fire behavior is part of the test plan.
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PA 12 GB
Status: PlannedGlass-bead-filled for stiffer fixtures and gauges with better dimensional stability.
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PA 11
Status: PlannedHigher ductility for clips, snap-fits and parts that must flex without cracking.
Specific powder grades are confirmed per project. Datasheets are shared on request, and we publish property values only once they are verified.
Compare materialsProduction platform
EOS P 770
Status: Commissioning Installed and being commissioned. Requests are reviewed now; production slots are confirmed per project.An industrial dual-laser polymer SLS system. Every status on this site comes from one registry and is kept current.
- Build volume
- 700 × 380 × 580 mm
- Lasers
- 2 × 70 W CO₂
Manufacturer specifications (EOS GmbH). Usable part size, material suitability and achievable tolerances require engineering review.
Services and their status
- Engineering review
- Status: Available now
- Design for additive manufacturing
- Status: Available now
- SLS prototyping
- Status: Commissioning
- Low-volume production
- Status: Commissioning
- Standard finishing
- Status: Commissioning
- Extended finishing
- Status: Planned
- Inspection reports
- Status: Planned
How it works
From CAD file to finished part
Every request is quoted by an engineer, not by an algorithm. You get a clear answer on what can be built, how, and at what cost.
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CAD upload
Send STEP, STL or 3MF files, or drawings, with quantity, material and application details through the secure form.
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Engineering review
An engineer checks manufacturability, build orientation, material fit and any design changes worth considering.
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Quotation
You receive a written quotation with price, lead time and the recommendations from the review. If the part is outside our scope, we tell you why.
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Production
After your approval, parts are built, depowdered, finished as agreed and checked before dispatch.
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Start a project
Developing aerospace hardware?
Send drawings or CAD with the intended use and your documentation needs. We confirm what we can support before quoting, and if you ask for an NDA, it is signed before your files are reviewed.