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LFAM aerospace composite parts fly high with 3D printed autoclave molds image

Large-format 3D printing is transforming the production of autoclave molds for composite components, enabling faster, more flexible, and cost-efficient manufacturing processes. In aerospace applications, where precision and performance are critical, LFAM technology offers a new approach to producing complex tooling with reduced lead times and improved design freedom.

In this context, Caracol collaborated with Connova and Formbar to introduce LFAM into the production workflow of composite parts, including a drone nose manufactured through prepreg autoclave lamination.Connova-3

From design optimization to full-scale mold production

Starting from Connova’s 3D model, Caracol’s engineering team optimized the design for additive manufacturing and defined the most efficient printing strategy. The mold was produced using the Heron AM 400 platform equipped with a High Flow extruder, printing two monolithic parts with high precision and structural integrity.

The use of carbon fiber reinforced polycarbonate ensured the mold could withstand demanding autoclave conditions, including high temperature and pressure.

Production data

  • Technology: LFAM Heron AM (HF extruder) + CNC post-processing
  • Material: DAHLTRAM C-250 CF (PC CF)
  • Size and weight: 1100 × 1100 × 900 mm, 260 kg
  • Nozzle size: 12 mm
  • 3D printing time: 30 hours

Following printing, Formbar completed the process with 5-axis CNC machining to achieve aerospace-grade tolerances and surface quality, reaching 0.1 mm dimensional accuracy and 0.8 μm surface roughness.

Performance gains in tooling and production workflows

The integration of LFAM into autoclave mold production delivered measurable improvements across performance, cost, and efficiency:

  • Weight reduction: Up to 50% lighter compared to traditional molds
  • Waste reduction: Up to 40% less material waste
  • Lead time reduction: Up to 50% faster production cycles
  • Cost savings: Around 30% reduction in overall production costs
  • Process optimization: Single monolithic print eliminating assembly and manual operations

The first component produced using this mold—a carbon fiber drone nose—validated the effectiveness of LFAM in real industrial conditions.

A new standard for autoclave mold manufacturing

Compared to traditional methods such as CNC machining or manual tooling, large-format 3D printing enables a more agile and sustainable approach to mold production. Complex geometries can be realized quickly, with minimal waste and reduced dependency on labor-intensive processes.

This project demonstrates how LFAM can redefine tooling in advanced industries, enabling faster development cycles, improved performance, and greater design flexibility. By combining advanced materials with robotic additive manufacturing, Caracol is supporting the evolution of high-performance composite production.

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