BAE Systems Propels Aerospace Innovation with Advanced Stratasys 3D Printing Technology

The aerospace sector stands as a pioneering industry in the adoption of additive manufacturing (AM), particularly metal 3D printing. From the early stages of prototype development to the production of critical spare parts and even highly functional end-use components, AM has revolutionized how aircraft are designed, built, and maintained. Its applications span a vast range, including the creation of intricate turbine blades, complex engine components, ergonomic aircraft seats, and various structural elements. The escalating popularity of additive manufacturing in aerospace is driven by its unparalleled ability to facilitate the design of more intricate and lighter parts simultaneously, which is crucial for fuel efficiency and performance. Furthermore, the technology offers significant advantages in terms of accelerated production cycles and reduced manufacturing costs, making it an indispensable tool for modern aerospace engineering. While aerospace was an early adopter, AM’s influence now extends far beyond aeronautics, transforming manufacturing processes across land vehicles, complex maritime vessels, and numerous other industries. Among the global leaders embracing this transformative technology, BAE Systems stands out as a prime example of strategic integration and innovation.

BAE Systems, a multinational aerospace, defense, and security powerhouse headquartered in the United Kingdom, operates at the forefront of global security. The company specializes in the design, manufacturing, and comprehensive support of complex surface ships, advanced combat vehicles, sophisticated artillery systems, cutting-edge missile launchers, and both combat and trainer aircraft. This extensive portfolio means BAE Systems provides crucial defense and security solutions across Land, Air, and Sea domains. With innovation and operational efficiency being paramount to their mission, BAE Systems recognized and embraced the transformative value of additive manufacturing technologies over two decades ago. This foresight allowed them to integrate AM into their operations well before it became mainstream. By 2016, the British defense giant had already successfully 3D printed more than 2,500 parts, demonstrating a deep commitment to the technology. A notable achievement includes the integration of 3D printed components into the formidable Typhoon fighter aircraft. For instance, the cockpit floors for the Typhoon were meticulously produced using ABS (Acrylonitrile Butadiene Styrene) and ASA materials. These materials were specifically chosen for their excellent mechanical properties, durability, and resistance to environmental factors, providing reliable and lightweight solutions in a demanding aerospace environment.

Additive manufacturing enabled BAE Systems to design and enhance components for the Typhoon fighter aircraft. (Credits: BAE Systems)

In a testament to its ongoing commitment to advanced manufacturing, BAE Systems announced earlier this year a significant new agreement with Renishaw, a global leader in engineering and scientific technology. This strategic move involved a substantial investment in several Renishaw 3D printers, which have been deployed at BAE Systems’ cutting-edge product and process development center located in Samlesbury, Lancashire. This investment complements their extensive existing portfolio of additive manufacturing solutions, notably those from Stratasys, with whom BAE Systems shares a remarkably long and fruitful history of collaboration. The partnership between these two industry giants commenced way back in 2006 when BAE Systems made a pivotal decision to invest in Stratasys’ pioneering 3D printing technologies. This early adoption marked the beginning of a sustained effort to integrate Fused Deposition Modeling (FDM) technology into their critical operations, leveraging Stratasys’ expertise to produce robust and reliable parts for various applications across their defense and security programs.

The strong alliance between Stratasys, a global leader in polymer 3D printing, and BAE Systems, a titan in aerospace and defense, continues to deepen. Just recently, BAE Systems confirmed the acquisition of their fourth industrial Stratasys 3D printer. This latest addition significantly bolsters their existing line-up of Stratasys F900 industrial 3D printers, which are renowned for their reliability, large build volumes, and ability to process high-performance thermoplastics. These F900 machines are engineered to operate continuously, around the clock, forming an indispensable cornerstone of BAE’s visionary “Factory of the Future.” This state-of-the-art facility, spanning 1,000 square meters in Lancashire, is designed to be a paradigm of modern manufacturing where the most advanced digital and robotic technologies seamlessly integrate with human expertise. The Factory of the Future embodies BAE Systems’ commitment to pioneering new production methodologies and driving technological advancements in defense manufacturing. Greg Flanagan, Additive Manufacturing Operations Lead at BAE Systems Air, highlighted the strategic importance of this collaboration: “Our Factory of the Future program is all about driving the future of fighter aircraft production with disruptive technologies, and we’re working closely with our suppliers and wider industry to meet the challenges the UK Government has set out to us. Stratasys FDM additive manufacturing plays an important role in this initiative, as it helps us meet our overall company objectives to reduce costs and time-to-market.” This statement underscores how FDM technology, particularly through the robust capabilities of the F900, is critical in achieving BAE Systems’ ambitious goals of efficiency, cost reduction, and accelerated product development cycles.

The progression of BAE Systems’ additive manufacturing strategy is striking. Historically, only about 1% of the components for the Typhoon fighter aircraft were produced using additive manufacturing processes. However, BAE Systems is now setting an ambitious new benchmark: aiming to 3D print a remarkable 30% of parts for its next-generation Tempest aircraft. This significant increase from 1% to 30% represents a monumental shift in manufacturing philosophy and a profound commitment to leveraging AM’s full potential. The primary drivers behind this aggressive integration are the urgent goals of substantially increasing production speed and drastically reducing overall production costs, both critical factors in developing advanced defense platforms. This strategic imperative directly led to the acquisition of yet another FDM printer, as the technology proves invaluable for rapidly producing strong, lightweight, and complex parts at scale. The ability to iterate designs quickly, produce customized components on demand, and consolidate multiple parts into single, optimized structures directly contributes to the agility and cost-effectiveness required for projects as complex as the Tempest fighter jet. The FDM process allows BAE Systems to experiment with novel designs, pushing the boundaries of what’s possible in aerospace component development.

BAE Systems proudly adds its fourth Stratasys F900 3D printer to its expanding fleet, solidifying its commitment to the “Factory of the Future” initiative. (Credits: BAE Systems)

Elaborating further on the tangible benefits, Greg Flanagan highlighted specific applications where FDM 3D printing delivers immediate and significant advantages. He explained, “With our FDM 3D printers, the thermoplastic covers can be made much faster than traditionally manufactured versions and are a lot lighter and easier to move for the ground crew, so it improves efficiencies within the maintenance, repair and overhaul process.” This statement underscores how additive manufacturing directly contributes to operational efficiency not just in production, but throughout the entire lifecycle of an aircraft. The rapid fabrication of these thermoplastic covers means that replacement parts can be created on-demand, reducing lead times and minimizing aircraft downtime. Furthermore, the inherent ability of FDM to produce lightweight components is a considerable advantage. Lighter covers not only reduce the overall weight of the aircraft, contributing to better fuel economy and performance, but also significantly ease the burden on ground crews responsible for maintenance, repair, and overhaul (MRO) operations. This ergonomic benefit leads to improved safety, reduced labor, and faster turnaround times for maintenance tasks. An ingenious added bonus is the ability to print these specific covers in red – the internationally recognized color for all ‘remove before flight’ components. This simple yet effective customization directly enhances safety protocols by making critical pre-flight removal items instantly identifiable, ensuring proper procedures are followed and minimizing human error during crucial pre-flight checks. The agility of FDM technology allows BAE Systems to implement such practical, impactful design choices directly into their manufacturing process.

The strategic partnership between BAE Systems and Stratasys exemplifies how collaborative innovation and advanced additive manufacturing can redefine the future of defense and aerospace production. As BAE Systems continues to push the boundaries with its Factory of the Future initiative and its ambitious goals for the Tempest aircraft, the role of 3D printing will only grow in importance, driving unprecedented levels of efficiency, cost-effectiveness, and design freedom. This evolution promises to deliver next-generation defense capabilities at an accelerated pace, ensuring technological superiority and operational readiness. What are your thoughts on this groundbreaking partnership and its implications for the aerospace and defense industries? We invite you to share your insights in a comment below or engage with us on our Facebook and Twitter pages. Your feedback is valuable, and we hope this detailed overview has been insightful! Don’t forget to sign up for our free weekly Newsletter, ensuring you stay up-to-date with all the latest news and developments in the dynamic world of 3D printing, delivered directly to your inbox!