Additive Manufacturing for Aerospace & Defense

Driving Manufacturing Efficiency – MRO and the Aircrafts of Tomorrow

From fast custom tooling to large surrogate parts and digital inventories, AON3D printers help OEMs, MROs, Tier suppliers, and eVTOLs revolutionize their manufacturing processes. Ungated access to the world’s most advanced thermoplastics and a massive build volume provide 90%+ reduction in costs and lead times for thousands of aviation and space applications..

Get a Quote

Fast, Custom Tooling for Manufacturing and MRO

Save weeks and thousands on a per part basis with on-demand tooling. The AON M2+ is a proven versatile tooling solution for maintaining, assembling, and fabricating aerospace components and assemblies.

Custom Jigs & Fixtures

Improve manufacturing efficiency with same-day custom jigs and fixtures capable of withstanding the most demanding applications.

Surrogate Parts

Manufacture full-scale placeholder parts for use in training and manufacturing processes which are later replaced in final assemblies.

Metal-Forming Dies

Create high strength dimple dies, press brake dies, hydroforming tooling, and more with the world’s strongest thermoplastics.

Mold Tooling

From vacuum forming to composite molds, high temperature 3D printing provides a fast, affordable, and durable tooling solution.

Case Study

Prototype & Bridge Tooling

Whether developing new tooling or waiting for production, high temperature 3D printing provides a quick and affordable solution.


Digital Warehousing – Transform Physical to Digital Inventory

Free up hundreds of thousands of dollars in tooling inventory with on-demand manufacturing. Utilizing digital inventories and AON3D printers, engineers can stay ahead of supply chain disruptions, mitigate part obsolescence, and transmit parts wirelessly across the globe in seconds.

Short Run End-Use Parts & Functional Prototypes

With high temperature 3D printing, engineers can print parts in high-performance materials with proven use cases in highly regulated industries, such as aviation.

Cabin Interior Components

3D print UL94 V-0 flammability rated materials that meet FAR 25.853 flame, smoke and toxicity (FST) requirements, such as ULTEM™ 9085


3D print materials, such as PEEK and PEKK, that can maintain mechanical properties under extreme thermal cycling and exhibit low outgassing under vacuum.

Unmanned Aerial Systems (UAS)

3D print materials with better strength to weight ratios than many metals for lightweight, high strength Unmanned Aerial Systems.

Functional Prototypes

Print parts that meet funcional requierments with access to the best mechnical, thermal, and chemical resistive properties currently available in 3D printing.

Access Aerospace Grade Materials

ULTEM™ 9085

A high strength, thermally stable, and chemical resistive material that meets many FAA or EASA regulations including UL94 V-0 flammability rating and FAR 25.853 (FST) requirements.

  • High Tensile Strength
  • Lightweight Metal Replacement
  • FST Compliant
More Details


An easier-to-print high performance polymer with great mechanical properties under thermal cycling, radiation and chemical resistance, and exhibits no outgassing under vacuum.

  • Extreme Thermal Resistance
  • High Tensile Strength
  • Easier to Print
More Details

CF Nylon

A low-cost, high strength, and rigid material that is perfect for functional prototypes, lightweight end of arm tooling, and many other tooling applications.

  • High Stiffness
  • Strong & Durable
  • Affordable
More Details


Compliant with RoHS Standards, ABS ESD is low-cost solution for fixtures when handling aircraft parts susceptible to damage from electrostatic discharge.

  • 107– 109 Ω Surface Resistivity
  • Durable
  • Affordable
More Details

Ungated Materials

With Open Materials engineers are free to print the materials they want with the part properties the need and at affordable prices. Discover what’s possible on our materials page.

  • No Unlock Fees
  • Access High Performance Materials
  • Explore & Develop New Materials
Explore Materials

Bring High Performance 3D Printing In-House

Not ready for a quote? No worries.
Download Hylo Spec Sheet and Request a Demo.