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3D Metal Printing for the Aerospace Industry


Direct Metal Laser Sintering (DMLS)/DMLM is perfectly suited for 3D metal printing of aerospace and UAV parts. Manufacturing aircraft parts with 3D printing enables our clients to adhere to strict thermal, weight reduction and complex part requirements. Using 3D metal printing in the aerospace industry is also beneficial, as this type of printing holds tolerances off the printer as tight as +/- .002 and prints densities above 99%. This makes tighter tolerance and post-process requirements easily achievable. Our most popular metals used in the 3D printing of aircraft parts and UAV components are Inconel, Haynes, Monel K (thermal properties), aluminum (thermal and weight advantages), and titanium (weight and strength).

Aircraft Rapid Prototyping

Rapid prototyping using 3D printing has been utilized by the aerospace industry for years. i3D MFG uses Direct Metal Laser Sintering (DMLS/DMLM) to create designs that cannot be traditionally machined or cast.

UAV/UAS Solutions

UAV/UAS applications are useful in both military and civilian applications. From agriculture to emergency response and mapping, i3D MFG manufactures small, lightweight, and incredibly durable UAVs that cannot be traditionally machined or cast.

Spacecraft & Rockets

3D metal printing is a cost-effective solution in the manufacturing of spacecrafts and rockets, as its directed lasers fuse materials together precisely where the part is built, resulting in no waste or scrap metal. This reduces the cost of printing in exotic metals such as titanium and Inconel by 50-70%.

i3D MFG™ is ITAR registered with the U.S. Department of State and follows ITAR protocols in its Bend, Oregon and The Dalles, Oregon locations.
i3DMFG ITAR Certified

Metals We Print

i3D MFG™ offers a vast selection of DMLS/DMLM standard metal powders. We also specialize in copper, titanium, Inconel, Hanyes, and custom powder applications. An EOS North America MPA (Material Process Applications) partner, our engineers help our customers achieve competitive advantages in design and proprietary advancements.

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Aluminum (Al)

Our most common DMLS or DMLM aluminum powder is AlSi10. This powder is ideal for projects that require good thermal and low weight considerations. It is equally ideal for parts with thin walls and complex geometries.

Titanium (Ti)

Well suited for medical device, aerospace, UAV/UAS, Defense, firearms, oil & gas, energy, and automotive projects, Ti64 offers superior corrosion resistance, strength, weight reduction, and biocompatibility.

Stainless Steels

Useful in medical device, defense, firearms, energy, and automotive applications, our stainless steel is a medical-grade and corrosion-resistant steel that can be sterilized. After heat treatment, PH1 hardens to 40-45 HRC. Our stainless-steel equivalents include 15-5, 17-4, and .316. Parts made from EOS stainless steel PH1 can be machined, spark-eroded, welded, micro shot-peened, polished, and coated.

Maraging Steel

Most commonly used in tooling applications, maraging steel powder, or MS1, features superior strength and mechanical properties. This pre-alloyed, ultra-strong steel powder’s chemical composition parallels U.S. 18% Ni Maraging 300, European 1.2709 and German X3NiCoMoTi 18-9-5. After heat treatment, MS1 typically has a 50-53 HRC.

Inconel (IN718)

Ideal for use in the rocket, space, aerospace, firearms, energy, and automotive industries, Inconel, or IN718/INC625, are chromium alloys with superior heat resistance. This DMLS or DMLM nickel typically features a heat treatment hardness of 40-47 HRC (370-450HB).

Custom Powders

i3D MFG™ is the market leader in custom DMLS or DMLM powder development. We have access to the latest DMLM/DMLS machine parameter sets and i3D™ to develop highly specialized powder applications for aerospace, rocket, automotive, and casting customers.

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  • 3525 Crates Way, The Dalles, OR, 97058
  • 541.588.0986