Aerospace 3D printing

The aerospace industry is an early adopter of 3D printing technology. Experts were quick to recognise the great potential of this cost- and resource-saving production technology, which offers the possibility of manufacturing even complex geometries without restrictions in terms of functionality and material. Ensinger combines more than 50 years of experience in the field of thermoplastics with the highest level of expertise in 3D printing for the aerospace industry. We create solutions for complex designs, helping to reduce fuel consumption and CO2 emissions by saving material and weight.
From tailor-made compounds in our in-house compounding facility, through our own aerospace-specific extruded filaments, to the finished 3D printed aircraft part, we are able to cover the entire value chain at Ensinger. This ensures the highest quality, expert advice at every stage of your project and complete batch traceability. 

Are you an aerospace OEM looking for individual, cost-effective solutions for small series and prototypes? We will be happy to advise you on your individual project.

Aerospace 3D printing with Ensinger

Benefit from:

  • A broad portfolio of materials optimised and qualified for our aerospace 3D printing processes
  • A production area optimised for aerospace additive manufacturing
  • Part designs that exploit all the benefits and capabilities of aerospace additive manufacturing technology
  • High-quality 3D-printed parts that meet FAR 25.853 requirements for aerospace use

Benefits of additive manufacturing for the aerospace industry

Production of lightweight parts saves costs and CO2

Innovative 3D printing technology allows lightweight but very strong structures to be produced. In addition, the use of high performance plastics leads to even greater weight savings. This enables cost-efficient, resource saving production that reduces the overall weight of aircraft, resulting in lower fuel consumption.

Demand-driven production without long production chains

From monitor to machine, few manufacturing technologies are as flexible as 3D printing. Changes to the product can be made on a customer specific basis. At the same time, we manufacture from batch size 1: extensive spare parts inventories thus give way to the lean processes of demand driven manufacturing. 

Certified and approved materials and components

Selected aerospace materials and filaments, as well as our industry specific 3D printers, are tested and certified to FAR 25.853, meeting the strict guidelines of the aerospace industry. Learn more about our comprehensive aerospace filament portfolio here.

Design freedom and innovative solutions

Complex geometries, innovative new approaches or the replacement of aircraft components previously made of metal. The possibilities and potential of 3D printing in aerospace are extensive. We can advise you on the many options available and help you create the CAD that is the basis for production.


From compound to component - One-Stop Shop for 3D printed aerospace parts

Additive manufacturing process at Ensinger
As a solution provider for 3D printed aerospace parts, we can cover the entire value chain in-house. With our own compounding facility and filament extrusion, we manufacture materials that are perfectly matched to our 3D production and aerospace applications. We also cover all post-processing steps under one roof. This ensures the highest quality, efficient project management and applications precisely tailored to your needs.

Case stories and application examples

Gear wheel made from TECAFIL PVDF natural, 3D printed and machined

  • Material savings (compared to CNC milling)
  • Time savings: complex preparations are not requiered
  • Good sliding and wear properties 

Guiding, 3D printed and machined

  • Made from TECAFIL PPSU natural
  • Combination of additive and subtractive production processes
  • Lightweight construction: Weight reduction by hollow-chamber structures
  • High stiffness and strength

Lightweight strut , 3D printed and machined

  • Made of TECAFIL PEEK natural
  • Honeycomb structure allows 3D printing from both sides, a capability not feasible withany other method
  • Significant weight reduction
  • Constant stability

Race car

Race Car Engine Components

made with TECAFIL PEI 9085

Flame Retardant Filaments for Race Car Components

Our TECAFIL PEI 9085 filament is inherently flame retardant, certified to UL94-V0 and meets Flame, Smoke & Toxicity safety standards. 3D printed components made with the filament are therefore perfectly suited for race car applications. Together with development partner DREIGEIST, StarkStrom Augsburg e.V. successfully uses Ensingers 3D printing filament TECAFIL PEI 9085 natural for parts of the race car´s engine. Read more about the exciting application here!