AIM3D Certifies ExAM A 510 for Aerospace ULTEM 9085 Parts

Certification Focuses on Process Consistency

The certification process required ULTEM 9085 test specimens to have consistent tensile strength across different machines and build positions. This is a challenge due to variations in temperature and airflow across the build platform, which can affect layer bonding and part quality. AIM3D addressed this by ensuring that all process parameters were tightly controlled and standardized. This approach helps maintain uniformity in the final product, which is essential for aerospace applications where reliability is paramount.

AIM3D treated the entire printing process as a certified system, not just the machine. All process parameters were documented, standardized, and optimized to ensure traceability and compliance with aerospace regulations. This level of documentation is crucial for aerospace manufacturers, who need to maintain detailed records of every step in the production process. By locking down these parameters, AIM3D ensures that the ExAM A 510 can be used in regulated environments without compromising quality or safety.

The ExAM A 510 features a chamber heated on all sides to maintain thermal uniformity, reducing residual stress and warping. This design helps achieve consistent part quality, which is critical for aerospace applications. Thermal uniformity is essential for high-temperature thermoplastics like ULTEM 9085, as it prevents uneven cooling and ensures that each layer bonds properly. This design choice reflects AIM3D’s commitment to producing reliable, high-quality parts for the aerospace industry.

Thermal Uniformity Enhances Part Quality

The system also includes modifications for uniform temperature distribution and controlled material feeding. These changes ensure that ULTEM 9085 is processed consistently, improving part reliability and performance. By maintaining a stable thermal environment and controlling the material feed, the ExAM A 510 minimizes the risk of defects and ensures that each part meets the required specifications. This level of control is vital for aerospace components, where even small deviations can have significant consequences.

The ExAM A 510 replaces the standard viewing window with a camera for monitoring the build chamber. This change supports real-time process control and quality assurance during printing. The camera allows operators to monitor the printing process without compromising the thermal integrity of the chamber. This feature is particularly useful for ensuring that the printing process remains stable and that any issues are detected early, preventing potential failures in the final product.

AIM3D collaborated with AM-MRO GmbH to develop the system and meet aerospace standards. AM-MRO provides consulting, training, and auditing services to ensure compliance with aviation requirements. This partnership highlights the importance of working with specialized experts in the aerospace industry. By leveraging AM-MRO’s expertise, AIM3D was able to ensure that the ExAM A 510 met all necessary regulatory and quality standards, making it suitable for use in critical aerospace applications.

Documentation and Standardization Are Key

The certification combines high mechanical performance with process stability, making the ExAM A 510 suitable for aerospace manufacturing. This includes support for on-site production and part optimization. The ability to produce parts on-site reduces lead times and improves supply chain efficiency, which is especially valuable in the aerospace industry. The ExAM A 510’s design allows for flexible production, enabling manufacturers to meet specific requirements without compromising quality or reliability.

The ExAM A 510 offers a higher density than filament-printed parts, which can improve mechanical properties. This makes it a viable option for aerospace components requiring high strength and reliability. The higher density of parts produced by the ExAM A 510 results from the controlled feeding and thermal management of the material. This advantage is particularly beneficial for applications where structural integrity is critical, such as in aircraft components and other high-stress environments.

Aerospace Standards Drive Development

The system’s design allows for easy removal of support structures, streamlining post-processing. This feature is important for reducing labor and improving efficiency in production workflows. By minimizing the time and effort required for post-processing, the ExAM A 510 helps manufacturers save time and resources. This efficiency is essential in aerospace manufacturing, where cost and time are significant factors in the production process.

The ExAM A 510 is set to be showcased at Formnext 2026, highlighting its potential for aerospace applications. This event will provide further insight into its capabilities and industry adoption. Formnext is a major event in the additive manufacturing industry, and the showcase of the ExAM A 510 will allow potential customers and partners to see the machine in action. This exposure is expected to increase interest in the ExAM A 510 and encourage its adoption in the aerospace sector.

The certification of the ExAM A 510 reflects the growing demand for reliable, high-quality 3D-printed aerospace components. It addresses the need for consistent, traceable manufacturing processes in regulated environments. As the aerospace industry continues to adopt additive manufacturing, the demand for certified, high-quality 3D printers like the ExAM A 510 is expected to grow. This certification positions AIM3D as a leader in the development of advanced 3D printing solutions for aerospace applications.