How Aerospace 3D Printing in Derby is Transforming Manufacturing and Innovation

By Sam Gribben
September 25, 2025
1:30 pm

Derby is known globally for its aerospace excellence, home to world-leading manufacturers and suppliers. From jet engine components to lightweight cabin fittings, aerospace 3D printing Derby is accelerating production, improving performance, and enabling rapid innovation.

At SGD 3D, we provide ISO 9001-certified FDM, SLA, and SLS printing to aerospace companies in Derby, helping them prototype, test, and produce parts faster and more cost-effectively than ever before.

Rapid Prototyping for Aerospace Components

In aerospace engineering, precision and speed are essential. Traditional prototyping can take weeks, but with aerospace 3D printing Derby manufacturers can:

Produce functional prototypes in days.
Iterate designs quickly without costly tooling changes.
Validate complex geometries before committing to production.

Lightweight, High-Strength Materials

Weight reduction is critical in aerospace to improve fuel efficiency and reduce emissions. With advanced materials such as PEEK, ULTEM1010 and Nylon PA12 GF, 3D printing enables:

Hollow and lattice structures for weight savings.
Strong, durable parts that meet aerospace performance standards.
Integration of multiple parts into a single lightweight component.

Source: Stratasys

Custom Tooling and Jigs

Production lines in the aerospace industry rely on precision tooling. 3D printing allows Derby manufacturers to:

Create customised jigs and fixtures tailored to specific aircraft models.
Reduce production downtime with fast-turnaround replacements.
Improve safety with lighter, ergonomic tools.

We’ve delivered SLS 3D Printed fixtures to hold complex forms for welding operations. To ensure both halves met with absolute precision, the flange was semi-finished using a vertical machining operation. We assisted the end-customer re-design their part so that it could be mounted onto a standard tooling plate to make clocking-in easier for the CNC operator.

Source: Ultimaker

Low-Volume and Spare Parts Production

For older aircraft or specialised models, sourcing spare parts can be a long and costly process. With 3D printing:

Obsolete components can be reverse-engineered and printed on demand.
Low-volume production runs are cost-effective without tooling investment.
Parts can be supplied faster, reducing aircraft downtime.

Driving Collaboration in the Midlands Aerospace Cluster

Derby’s aerospace ecosystem is interconnected with other Midlands cities. 3D printing supports collaboration between manufacturers, research centres, and educational institutions.

With Birmingham: Automotive manufacturers are using similar additive manufacturing processes — see Automotive 3D Printing in Birmingham for how these innovations overlap.
With Nottingham: Universities and research facilities are working on aerospace material development — read our blog on Education 3D Printing in Nottingham to see how this supports aerospace R&D.

Sustainability in Aerospace Manufacturing

Sustainability is becoming a key focus in aerospace. 3D printing in Derby helps by:

Reducing material waste compared to CNC machining.
Allowing localised production to cut transportation emissions.
Supporting the use of lightweight materials for better fuel efficiency.

At SGD 3D, we offer eco-conscious material options, helping aerospace manufacturers meet environmental targets without compromising performance.

Aerospace 3D printing in Derby is revolutionising the way aircraft parts are designed, tested, and produced. With faster prototyping, lightweight materials, custom tooling, and on-demand production, local manufacturers are gaining a competitive edge in a highly demanding industry.

📦 Get started today: Order 3D printed parts in Derby — upload your file for an instant online quote.

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