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3D printed tools for aircraft manufacturing image

As the aerospace industry continues to lead the adoption of additive manufacturing, LFAM technologies are increasingly used for tooling applications. Tools, jigs, and fixtures represent a key area where large-format 3D printing can significantly improve manufacturing processes and supply chains.

Leveraging its expertise in AM, design for additive manufacturing, and engineering, Caracol has developed its Heron AM platform to produce high-performance tooling, certified according to AS/EN 9100 standards and suitable for demanding aerospace applications.01 3D printed tools for aircraft manufacturing

 

Advanced tooling production with Heron AM

Caracol has produced a wide range of tooling solutions, including jigs and fixtures for drilling, trimming, milling, and assembly, as well as inspection tools and master molds for composite manufacturing.

Using the Heron AM 300 platform equipped with a High Flow extruder, Caracol manufactured trimming and drilling tools, as well as cold lamination molds for aircraft fuselage production and maintenance. These tools were produced as single monolithic parts, eliminating assembly and improving structural integrity.

The platform processes a wide range of composite thermoplastics, including ABS, polypropylene, polycarbonate, and high-performance materials, enabling the production of tools tailored to different thermal and mechanical requirements.

Production data

  • Technology: LFAM Heron AM (HF extruder) + CNC post-processing
  • Material: ABS + glass fiber
  • Size: 1650 × 1000 × 400 mm
  • Weight: 100 kg (up to 80% reduction)
  • Surface roughness: 1.2 μm
  • Dimensional tolerances: 0.2 mm

After printing, parts were CNC machined to achieve the required tolerances and surface finish for aerospace applications.

Benefits and industrial value

The adoption of LFAM for aerospace tooling delivers significant advantages compared to traditional manufacturing methods:

  • Weight reduction: Up to 80% lighter tools, improving handling and logistics
  • Waste reduction: Up to 60% less material waste
  • Lead time reduction: From 12 weeks down to 5–6 weeks (around 50% faster)
  • Cost savings: Starting from 50% reduction
  • Process optimization: Single-piece production without assembly
  • Sustainability: Additive process reduces material consumption and environmental impact

This approach enables aerospace manufacturers to produce high-quality tooling faster, more efficiently, and with greater flexibility, supporting more sustainable and responsive production workflows.02 3D printed tools for aircraft manufacturing

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