In 2018, we delivered our first batch of specialized parts for gas supply lines, which included a 3D printed part for a regional airliner. Since then, Senior AerospaceBWT has provided their customers with hundreds of aircraft interior parts made with FDM technology that are lightweight and ready to fly.

After completing the necessary qualification reports and receiving approval, Senior Aerospace BWT has the ability to use 3D printing to produce internal parts that meet the requirements of aircraft manufacturers.

A member of Senior plc, SeniorAerospace BWT is an AS/EN/JISQ 9100:2016 certified global manufacturer specializing in ultralight low pressure air distribution systems for the aerospace industry.Senior Aerospace BWT is located in Greater Manchester, UK, and serves the regional aircraft, military, private and rotary wing aircraft markets.

With more than 10 years of experience in additive manufacturing, Senior Aerospace BWT began using Stratasys FDM® 3D printing technology several years ago to produce commercially viable parts for low-pressure air ducting systems and aircraft interior air conditioning.

Through a technical partnership with a print services organization, SeniorAerospace BWT learned that parts made with FDM technology could replace some traditional aluminum parts.

Initial studies have shown that FDM technology has tremendous potential in terms of part weight, cost, and lead time, all with relatively inexpensive installation setups compared to traditional manufacturing processes for aluminum parts.

In 2018, Senior Aerospace BWT, along with its technology partners, delivered its first gas supply pipe parts, which included a 3D printed part for a regional airliner. This was a Pitot tube made of traceable ULTEM™ 9085 resin material, a special design that can be realized with additive manufacturing, attached to a pipe for connection in a smoke detector. Since then, Senior Aerospace BWT has embraced FDM technology and to date has provided customers with hundreds of lightweight, ready-to-fly aircraft interior parts with highly complex geometries.

Senior Aerospace BWT can use 3D printing to produce AS9100-certified aircraft interior subassemblies for top-assembly components to meet customer requirements for specific aircraft applications

Guaranteed self-sufficiency with the purchase of only two Fortus® printers

The success of using FDM technology has set the stage for further investment in in-house production.In 2019, SeniorAerospace BWT installed two Stratasys Fortus 450mc™ 3D printers in its dedicated Additive Manufacturing Facility Center through local partner Tri-Tech3D.

After two years of intensive research and development work, SeniorAerospace BWT has received AS9100 certification for its products and processes. This means the company can now quickly and cost-effectively produce certified aircraft interior subassemblies for top assembly to meet customer needs for specific aircraft. These include aerospace OEMs for regional, military and private aircraft.

Statasys aerospace-grade materials have a number of advantages that SeniorAerospace BWT cites as key factors in their success.

Darren Butterworth, CEO of Senior Aerospace BWT, said, “The FDM Additive Manufacturing technology from Stratasys won us over with its ULTEM™ 9085 resin material, one of the most advanced and recognized materials for flyable aerospace parts. importantly, it enables lot traceability from part to source.

BWT's Additive Manufacturing team has seen FDM technology demonstrate significant and quantifiable benefits in terms of reduced part weight, lower costs and shorter lead times compared to traditional aluminum part fabrication processes. This is especially evident in projects involving multiple different parts, some of which may be only a few centimeters in size.

Using Stratasys aerospace-grade ULTEM™ 9085 resin material to produce parts provides BWT's customers with a robust, repeatable and traceable manufacturing process. Photo shows parts used in low-pressure air ducting systems.

Up to 75% efficiency savings

In many cases, aluminum parts have minimum order quantities, so when demand is low, it is not possible to manufacture parts for aircraft in this traditional way. With additive manufacturing technology, BWT was able to minimize inventory by printing a certain number of parts on-demand in a limited amount of time, utilizing the full build space of the Fortus450mc.

Says Butterworth, “In many cases, we've been able to save up to 75 percent by designing and manufacturing parts on the Fortus 450mc printer.” In addition to designing and manufacturing parts in-house, our team can use the 3D printers for a variety of tooling and R&D requirements. For these applications, Senior Aerospace uses wear-resistant polycarbonate thermoplastics and ABS materials to create strong and lightweight jigs, fixtures and other production aids on demand.

look to the future

With a certified in-house additive manufacturing capability, Senior Aerospace BWT hopes to drive the adoption of more 3D printed parts in aircraft, allowing the small batch and customized production features of 3D printing technology to bring even more benefits to its customers. The company also plans to utilize the technology in industries outside of aerospace (e.g., automotive and mobility) to expand its customer base and enable new business growth.

Looking ahead, Senior Aerospace BWT is already planning to invest in additional Stratasys FDM 3D printers. One of the company's key strategic goals is to utilize 3D printing technology to further drive innovation in product development and thus long-term business growth. To achieve this, additive manufacturing technologies need to be continually explored.

Utilizing the full build space of the Stratasys 450mc, Senior Aerospace BWT can print a certain number of parts on demand to minimize inventory