Blackpool firm joins world-first aircraft part 3D printing project

Blackpool-based aerospace specialist Airframe Designs has joined a project aiming undertake a world-first 3D printing of an aircraft part.

The National Aerospace Technology Exploitation Programme is an 18-month government-funded project to explore using a polymer in 3D printing to help the UK aerospace industry.

Garry Sellick, additive manufacturing manager at Airframe Designs, said: “We are building a database of materials which can be used in the parts being developed for the future. The project is aiming to be a world-first in airworthy part production using water-soluble support in the 3D printing process with faster manufacture and less potential for damage than current manual methods.

“We’re proud that we’re pushing the boundaries for the aerospace industry and it is a testament to Airframe Designs that we can help lead this important development with our engineering excellence.”

The project developing the Victrex AM200 polymer will be ongoing until later this year when it will be reviewed as part of the programme, a £20m government-funded initiative developing more than 80 different aerospace technologies across the UK supply chain.

The services offered by Airframe Designs are designed to meet the requirements applicable for the aerospace and defence sectors for lightweight ultra-polymer materials that can withstand high temperatures but also provide adequate strength and durability margins.

The aim of the project is to open up opportunities for flight-worthy parts within the aircraft cabin environment and aircraft interiors market. The technology can also be adapted for other industries including automotive, space, nuclear and rail.

Airframe Designs has recently been re-certified to AS9100D/BS EN ISO 9001:2015 for aerospace quality standards and achieved certification to ISO 14001 for effective environmental management systems. It also holds ISO 27001 certification for information security management and is accredited to Cyber Essentials Plus.

Recent projects undertaken by the company include the integration of new systems into heavy lift drone platforms, conceptual design at a platform level for new uncrewed air-systems, test rig and tooling for electric vehicle propulsion systems and most recently the design and analysis of operator consoles for a special mission aircraft.