3D PRINTING FOR AEROSPACE & DEFENSE INDUSTRY

Our 3D printing solutions meet the requirements of the aerospace and defense industry but also the civil and military robotics sector. Our innovative 3D printing technologies enable the design of parts with complex geometries or difficult aerodynamic properties if not impossible to manufacture with traditional methods for engine parts, turbine, aircraft wing or cabin interior .

You can now produce lighter components, increase yields of your critical parts and reduce spare parts inventory by producing on demand. With our industrial 3D printing solutions, reduce costs by eliminating your traditional tooling and shorten your development and manufacturing time for prototypes or functional parts.

ADDITIVE MANUFACTURING IN THE SERVICE OF AEROSPACE & DEFENSE INDUSTRY

AIRBUS HELICOPTER: CABIN VENTILATION DISTRIBUTOR

ECA GROUP UAV IT180-60: ELECTRIC MOTOR COOLING FAN

SOGECLAIR: PROSPECTIVE STUDY OF ENGINE PYLON

LOST WAX CASTING OF TURBINE BLADES

ECA GROUP: HUMANOID ROBOTS FOR DEFENSE & SECURITY

PRODWAYS AEROSPACE DIVISION

Prodways created a specific division dedicated to the aerospace industry, based in the European aerospace cradle in Toulouse in France, with a showroom dedicated to these industries. Our expertise, combined with the one of Group Gorgé in robotics, allows us to meet the requirements of civil and military aircraft manufacturers or maintenance and repair centers but also airline companies.

A COMPLETE 3D PRINTING OFFER DEDICATED TO AEROSPACE INDUSTRY

 

  • Tooling  and embedded parts manufacturing with over 30 years experience and a label EN9100 / ISO9001 (ECA Group)
  • Plastic and metal finished parts manufacturing through our fleet of thirty industrial 3D printers with ISO9001 certified technologies and materials (and EN9100 in progress).
  • Developing machines and materials on all 3D printing technologies

Come and meet us in our showroom base in Toulouse.

This division can count on the industrial experience of:

  • Initial, parts manufacturing subsidiary of Prodways group, with 15 years experience of producing plastic and metal parts in 3D printing in aerospace. Its fleet of thirty industrial 3D printers, including a dozen metal, covers a wide range of technologies and certified plastic and metal materials.
  • Prodways Technology, high level international company in developing industrial 3D printers and additive manufacturing materials.
  • The Aerospace division of  ECA Group, a subsidiary, as Prodways, of Groupe Gorgé, with 30 years of experience in production, inspection and maintenance tooling in the aerospace sector.

Based on experience and existing resources of Groupe Gorgé companies, we are the only company in the 3D printing industry capable of quickly implementing a team and ressources adapted to defense industry requests. An ad hoc organization is created, gathering the teams of the Prodways aerospace division and Groupe Gorgé competent companies to process your request in its entirety.

 

AIRBUS HELICOPTER, DASSAULT AVIATION, AIRBUS DEFENCE AND SPACE, Turbomeca, Sagem, CNES, THALES, SNECMA MOTOR SMA (SAFRAN Group), VISION SYSTEM AERONAUTIC, COMPOSITE INDUSTRY, REXIAA, CATHERINEAU, AIRCELLE TECHSPACE, RUAG and Cassidian, SOGECLAIR AEROSPACE, WANDERCRAFT, INFOTRON ™ TRUSTED INITIAL-PRODWAYS, ECA GROUP AEROSPACE & PRODWAYS GROUP.

AIRCRAFT PARTS & PROTOTYPES MANUFACTURING

Our Design Development and Part Production Center use highly technical polymers and metallic materials. From the creation of prototype parts through to the manufacturing of flight parts, we propose solutions tailored to your specifications.

WHY WORK WITH US ?

 Our Development and Production Center, certified ISO 9001, is capable to providing valuable services:

  • Study and design your parts
  • Produce and test your prototypes
  • Manufacture your prototypes and series parts
  • Provide more than 15 certified and qualified materials for aerospace: V-0 / UL 94 (Ultem®)/ FAR 25
  • Provide manufacturing and topological optimization
  • Quality control for your parts

Confidentiality: We guarantee full project confidentiality

Flexibility: The large production facility ensures continual production of your parts

Global Offer: A dedicated project manager will ensure full coordination for each phase of product development. He/she works closely with Product Design & Engineering experts through production and finalization.

STUDY AND DESIGN YOUR PARTS

Our creative and design team provides quality service (ISO 9001) and advice on the choice of materials to be used and the technologies best suited to your projects.

Whether you are a manufacturer of engines or complete vehicles, we offer solutions that can be customized to meet your needs.

PRODUCE AND TEST YOUR PROTOTYPES

Additive manufacturing is a rapid process allowing innovative development of all your projects. We offer a wide range of materials to meet your needs. The shape, adaptability and functionality of your parts can therefore be validated.

We have been providing specialized testing for production units as well as test equipment for more than 30 years. Applications may include:

  • Prototyping and validation of shapes
  • Functional testing
  • Controlling the form and geometry for compliance and functionality
  • Reducing costly modifications of production tools
  • Reducing functional kinematic assemblies (insertion, tolerance testing, etc.)

PRODUCTION OF SERIES PARTS

We provide one of the largest production facilities in France and can provide materials well-suited to the environment and the use of your parts:

Direct Metal Laser Sintering®

  • Inconel 718 et 625
  • Hastelloy X
  • Titane TI 64, TI 64 ELI
  • Inox 316L
  • Aluminium
  • Chrome – Cobalt

Plastic Additive Manufacturing

  • PA2210 FR
  • PA2241 FR
  • PX330
  • PEI (Ultem® 9085)

MAnufacturing and topological optimization

Our expertise in additive manufacturing and the capacity of our production facility allow us to revolutionize the “traditional” design of parts by using efficient structural methods and topological optimization.

Using your specifications, we can:

  • Re-design your parts and sub-assemblies for full optimization
  • Design your optimized parts:
    • Reduce weight
    • Reduction in the number of references to manufacture
    • Wholesale orders, stock management
    • No tooling
    • Eco-design

CONTROL YOUR PARTS

3D control by comparison is a modern and effective means to analyze and validate multiple parts.

  • We provide a control report
  • We make validation certificates available for our digitizing material
  • Exhaustive control testing is performed on the entire part
  • Simultaneous dimensional and geometry control
  • 3D vizualization software.

 

 

3D PRINTERS & MATERIALS FOR THE AEROSPACE & DEFENSE INDUSTRY

Prodways offers high performance 3D printing technologies and materials for aerospace and defense industry. We offer industrial production solutions to meet a wide range of applications: prototypes, parts for functional testing, master models for lost wax casting or direct production of durable plastic parts.

Moreover, we are accelerating innovation for our customers and open new opportunities for high-performance materials for R & D departments through our open material strategy on all our 3D printers ranges.

HIGH PRECISION MASTER MODELS  FOR FOUNDRY

Additive manufacturing MOVINGLight® technology is ideal for high precision master patterns for complex aircraft parts as blades reactors or components of aircraft engines, with a demanding dimensional tolerance and roughness to:

  • Validate the aerodynamic properties of your parts via 3D printing your prototype before tooling manufacturing. This saves the cost and time of injection molds manufacturing for prototyping stage while facilitating the necessary iterations to finalize your prototypes.
  • Improve the performance of your master models with very high levels of detail and resolution compared to traditional wax, without risk of deformation of the master model
  • Melt directly your high value parts from the master model 3D printed at very high resolution with castable resins, to optimize the topology and performance of your parts by eliminating the constraints and limitations of master models manufactured by injection.

 

3d-printing-aerospace-casting-master-model

FUNCTIONAL LIGHT PARTS WITH COMPLEX GEOMETRIES

Our laser sintering 3D printers ProMaker P series allow you to print durable and strong plastic parts with superior mechanical properties, for functional parts with more complex, more efficient and lighter geometries than the traditional manufacturing techniques.

Strategic parts requiring “Fire Retardant” certification

Combined with our 3D printing material PA11-EN 106 “fire retardant” – which meets the strict criteria of fire delay grade of the Federal Aviation Regulations (FAR) *** – our additive manufacturing solutions allow you to produce small or medium series of functional parts with excellent resistance to vibration during take-off and landing phases. These features are not altered with temperature changes – for example, the retaining clips of the cables positioned behind the panels airplane, or for interior equipment of aircraft cabins.

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Functional polymer parts resistant to shock and temperature

We also provide loaded material for your components requiring high stiffness and resistance to temperature variations from -40 ° C to + 130 ° C, while maintaining good mechanical properties and excellent ductility for use over long years- perfectly suitable for example for components of military drones or sensors.

PROTOTYPE FOR FUNCTIONAL VALIDATION

Prodways laser sintering technology offers maximum productivity to reduce operational costs, exceptional accuracy and compliance on all your prototypes for functional validation, as well as excellent thermal stability for optimized mechanical properties.

Our large portfolio of 3D printing materials can meet a wide range of applications for the manufacturing of parts with complex design and superior performances, while reducing the number of parts and assembly needs – such as for prototyping of air conditioning ducts

OPEN PLATFORMS AND HIGH TEMPERATURE FOR AEROSPACE RESEARCH

All Prodways 3D printers ranges provide an open platform for R & D centers to develop their own applications and pushing innovation beyond traditional or existing technology methods.

In addition, our high temperature laser sintering 3D printers allow to work with new high performance 3D printing materials like PA6 to develop innovative applications for the direct production of final use parts.

OUR QUALITY CERTIFICATION

The aeronautics and aerospace industries are at the front line of a strictly-regulated marketplace. Mastering the standards and fully maintaining aeronautics and aerospace certification is a key strategic resource that the Prodways Group shares with its partners. Whether engineered for passenger transit or military applications, the extremely tough safety and reliability requirements target every single link in a procurement chain interlinking a hugely diverse cross section of suppliers and subcontractors.

 

 

The Prodways Group subsidiaries are certified and regularly audited:

  • our development, design parts and manufacturing center is ISO 9001 certified and EN9100 certification is in process
  • ECA Group aerospace is EN9100 and ISO 9001 certified.

 

Our assets

Prodways Group

Groupe Gorgé’s subsidiary: 1,500 employees, industrial group, worldwide distribution, activities focused on aeronautics, aerospace and defense

Complete industrial solutions: 3D printers, materials, development and parts manufacturing

R&D centers & Integrated production

Dedicated aerospace division in Toulouse, France

25 years of Support Client

Our offer

More than 30 years of experience in design of tooling and embedded parts

452,000 pieces manufactured by year

Product design & Engineering, 3D Scanning and inspection, prototype and series tooling, conformal cooling, thermoplastic injection, casting, finishing, vacuum casting, post-process

30 (3D) printers in our production facility, including 12 metal printers and more than 15 certified materials

Technologies : MOVINGLight®, SLS®, SLS® HD, Polyjet®, SLA®, FDM®, DMLS®

Our clients

Airbus Helicopter - Dassault Aviation -
Airbus Defence and Space -
Turbomeca - Sagem - Thales -
Snecma Moteur - SMA (groupe Safran) -
Vision System Aeronautic - Rexiaa -
Composite Industrie - Catherineau -
Aircelle - Techspace - ECA Group -
Sogeclair Aerospace - Infotron™ -
Wandercraft - Ruag et Cassidian -
CNES

Adoption of 3D Printing in aerospace is happening even faster than what we thought 6 months ago

Raphaël Gorgé, CEO

Based in the European aeronautics hub of Toulouse, France, the Prodways Group’s new Aerospace division has a showroom dedicated to the aerospace sector, showcasing our knowledge and technology offerings. Presented in this showroom are specialized tooling applications that are already in use in industrial operations at aeronautical manufacturing sites and examples of embedded parts developed on test equipment, which are entering mass production.