How Aerospace Inc. Saved 40% on Tooling Costs

In the highly competitive aerospace industry, speed to market and reducing overhead are paramount. When Aerospace Inc. faced skyrocketing costs for custom assembly line jigs and fixtures, they turned to Pro3DForge for a modern additive manufacturing solution.

The Challenge

Traditionally, Aerospace Inc. relied on CNC machining to produce complex aluminum jigs. This process took an average of 4-6 weeks and cost thousands of dollars per fixture. If a design revision was needed, the entire timeline restarted, causing significant bottlenecks on the assembly floor.

The Solution

Aerospace Inc. integrated two ProFDM 900 Industrial 3D printers into their facility. Utilizing high-strength carbon-fiber reinforced nylon, their engineering team could iterate on jig designs overnight.

• Material: CF-Nylon for high tensile strength and chemical resistance.
• Print Volume: The massive 900x600x900 mm bed allowed for printing full-scale wingspan fixtures in a single continuous job.
• Throughput: Dual extruders reduced print times by 30%.

The Results

Within the first six months of deployment, Aerospace Inc. reported a 40% reduction in total tooling costs and a 75% decrease in lead times for custom fixtures.

"The ProFDM 900 completely changed our workflow. We no longer wait weeks for machine shops; we design it on Monday and install it on the assembly line by Wednesday."
— Sarah Jenkins, Lead Manufacturing Engineer, Aerospace Inc.