#7 Aerospace Manufacturing and Design’s Best of 2021: Large format additive manufacturing for rapid form tooling

3D printing, composite materials, and a modular design create space-saving aircraft tooling.

3D-printed stretch form die after machining.
3D-printed stretch form die after machining.
Additive Engineering Solutions (AES) LLC

Eric Brothers, Editor - Manufacturing Group

Published December 23, 2021

Stretch forming dies are unique to each section of an aircraft’s fuselage. Since many are needed, the sheer volume of dies can pose a storage problem, with stacks of heavy dies taking up valuable space and requiring much labor to move, organize, and mount on the press.

Additive manufacturing (AM) – 3D printing – offers a solution.

Akron, Ohio-based Additive Engineering Solutions (AES) LLC has applied its ability to 3D print large-size composites to create lighter stretch forming dies with modular, interchangeable components for Spirit AeroSystems.

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