How Additive Manufacturing Transformed Defense and Aerospace Manufacturing

The defense industry is experiencing a powerful surge. According to Deloitte, the global market grew from $473.47 billion in 2024 to $506.9 billion in 2025 — a year-over-year jump of 7.1%. This growth is fueled by rising defense budgets, rapid technological advancements, and increasing demand for modernization worldwide.

In the U.S. alone, the Biden administration has requested a record $849.8 billion budget for the Department of Defense (DoD). While large defense contractors remain dominant, the expanding and diversifying market is opening doors for small and mid-sized companies. Their agility, niche expertise, and technological innovation position them to win contracts and collaborate on major programs alongside industry giants.

Stratasys 3D printers are at the forefront of industrial additive manufacturing in aerospace and defense. As one of the top players in a fragmented global market, Stratasys leads in polymer-based systems trusted for mission-critical applications. With a strong focus on repeatability and reliability, the company has become the go-to partner for defense contractors seeking lightweight, high-performance parts and tooling.

The Strategic Advantage of Additive Manufacturing

Stratasys 3D printers have transformed the defense and aerospace industry, enabling faster production cycles, certified flight-ready parts, and dramatic cost savings over traditional methods.

Faster Development Cycles – From months or years down to days or weeks.
Cost Reduction – 50–90% lower tooling and production costs.
Lightweighting – Significant weight savings through high-performance thermoplastics.
Design Freedom – Ability to produce complex, integrated components not possible with machining.
On-Demand Flexibility – Eliminating supply chain delays and producing critical parts in-house.
Certification-Ready Materials – ULTEM™ and Antero™ polymers meeting aerospace FST and ESD requirements.

Stratasys Additive Manufacturing Applications in Aerospace and Defense

Accelerating Aircraft Innovation

Aurora Flight Sciences demonstrated the possibilities of 3D printing by building and flying a jet-powered UAV in record time. With 80% of the airframe 3D printed using ASA, ULTEM™, and Inconel, Aurora cut build time by half and delivered a flight-ready aircraft capable of 150+ mph. This project showcased how AM enables rapid iteration, complex internal geometries, and lightweight yet durable designs.
Bell Helicopter turned to AM during an upgrade of the V-22 Osprey. By 3D printing polycarbonate and PPSF wiring conduits, Bell slashed production from six weeks to just two and a half days, saving costs and enabling multiple design iterations. The durability of AM thermoplastics also meant that prototypes stood up to fuels and hydraulic fluids where traditional epoxy parts would fail.

Driving Efficiencies on the Ground

BAE Systems, as part of its “Factory of the Future” initiative, deployed a fleet of Stratasys F900 printers for tooling, ground support equipment, and production parts. By replacing heavy metal ground equipment with lightweight thermoplastic alternatives, BAE improved efficiency, safety, and cost savings. Their Typhoon fighter cockpit covers, once made from wood and metal, are now 3D printed lighter, faster, and easier to handle.
Indaero, a Spanish aerospace supplier, applied AM to helicopter tooling for Airbus. A tool that once weighed 12 kg in aluminum was reimagined in ULTEM™ 9085, now weighing just 3 kg. This reduced operator workload, cut production time by 66%, and lowered costs by more than 50%.
GKN Aerospace adopted AM to reduce production downtime. When tooling broke, instead of waiting weeks for replacements, GKN simply 3D printed them. The result? Less backlog, 40% fewer concessions, and even functional prototypes—like a fully realistic aircraft windscreen housing—produced within hours.

Enabling Flight-Certified Components

Traditionally, aerospace parts undergo years of testing and qualification. Additive manufacturing is now producing certified, flight-ready parts that meet the industry’s strictest requirements.

Marshall Aerospace and Defence Group leveraged ULTEM™ 9085 resin to create certified ducting parts for aircraft, achieving a 63% weight reduction compared to aluminum while meeting stringent EASA standards for flame, smoke, and toxicity.
Lockheed Martin, in partnership with NASA’s Orion program, integrated over 100 3D printed parts into its deep-space capsule. By using ULTEM™ 9085 and Antero™ ESD (a PEKK-based polymer with electrostatic dissipative properties), Lockheed produced docking hatch covers, oxygen ducts, and tubing strong enough for spaceflight while cutting costs and lead times by orders of magnitude.

Redefining Rocket Development

Northrop Grumman tackled long tooling lead times in rocket motor development. Instead of waiting a year for traditional metal tools, they used Antero® 840CN03 (PEKK-based, solvent-resistant, ESD-safe) to 3D print 10-foot rocket motor molds. The result was a tooling cycle cut from 12 months to just 6 weeks, enabling faster test-firings and new business opportunities.

Training & Tactical Operations

Sheppard Air Force Base applied AM to military training, producing UAV replicas, antennas, and trainer components at a fraction of the cost of traditional manufacturing. The program saved $3.8 million to date, with projected savings of $15 million over 15 years.
Spectra Group, a global defense communications provider, invested in Stratasys Origin (P3 DLP) to produce field-ready end-use parts for secure communication systems. By moving away from outsourcing, Spectra accelerated product launches, cut costs, and now ships mission-critical components directly into deployment zones.

For defense and aerospace, additive manufacturing is no longer just a prototyping tool—it’s a mission enabler. Whether it’s getting aircraft off the ground faster, certifying spaceflight-ready parts, or training the next generation of airmen, AM is reshaping what’s possible in some of the world’s most demanding industries.

As these leaders show, those who embrace 3D printing today are already flying higher, faster, and smarter than their competitors.