Aerospace & Aviation Digital Manufacturing
Precision-Engineered. Flight-Tested. Certified Reliability.
In the aerospace industry, every gram saved translates directly into increased payload capacity, extended operational range, and improved fuel efficiency. At HIGH On 3D, we provide the certified digital infrastructure that helps aerospace manufacturers, defense contractors, and aviation engineers move past the limitations of traditional heavy assemblies and slow subtractive tooling.
By leveraging our industrial 3D printing setup across SLS, MJF, SLA, and DMLS, alongside high-precision CNC machining in Pune (Chakan MIDC & Narhe), we enable the production of high-complexity air ducting, lightweight structural brackets, and FST-compliant interior aircraft components topologically optimized for maximum performance and minimum mass.
Applying 3D Printing Across the Aerospace Lifecycle
Design Communication & Aero Testing
Scale concept models produced via SLA and high-detail resins with smooth surface finishes suitable for wind-tunnel aerodynamic evaluation.
Functional Validation & Prototyping
Rapid production of full-scale landing gear enclosures, cockpit control panels, and structural mockups in engineering-grade thermoplastics.
Pre-Production & Rapid Tooling
Low-cost fabrication of drill jigs, trim templates, mold inserts, and assembly fixtures to streamline production lines before committing to expensive hard tooling.
Flight-Ready End-Use Production
Scalable manufacturing of certified flight hardware, custom drone airframes, and interior assemblies with complete process traceability and batch-to-batch repeatability.
Part Consolidation & Topology Optimization
Redesign multi-part assemblies into single integrated components to eliminate weld points, lower assembly time, and reduce overall aircraft weight.
Primary Aerospace Applications
- Aircraft Jigs & Fixtures:Custom drill guides, holding templates, and alignment gauges delivered with 60% to 90% cost and lead-time savings compared to conventional machining.
- Flight Surrogates:On-demand placeholder hardware used for assembly training, fit testing, and build practice prior to installing final flight components.
- Low-Volume Structural Brackets:High-strength titanium and aluminum brackets produced via DMLS for securing interior systems, avionics, and life-support hardware.
- Cockpit & Cabin Hardware:End-use screen bezels, custom control knobs, interior light housings, and ducting assemblies optimized for ergonomics and low weight.
Qualified Aerospace Materials Matrix
| Flight Domain | Target Application | Engineering Requirements | Recommended Process | Qualified Material |
|---|---|---|---|---|
| Engine & Exhaust | Nozzle bezels, heat shields | High thermal resistance & structural integrity | SLS / DMLS | Glass-Filled Nylon / Inconel 718 |
| Air Management | Environmental ducting, bellows | Flame-retardant, flexible, lightweight | SLS / MJF | Nylon PA12 / PA11 |
| Cabin Interiors | Controls, bezels, seat trim | Smooth surface finish, FST compliance | SLA / PolyJet | Digital ABS / High-Temp Resin |
| Structural & Space | Mounting brackets, satellite links | Maximum strength-to-weight ratio | DMLS | Titanium (Ti-6Al-4V) / AlSi10Mg |
| Optical & Lighting | Headlight lenses, indicator covers | Crystal clear transparency & fine detail | SLA | Optical Clear Resin / PMMA-like |