How MatterHackers Empowers Aerospace Innovation with Advanced Digital Manufacturing

In the rapidly evolving world of aerospace engineering, staying ahead of the curve is not just an advantage—it's a necessity. As the industry faces mounting pressures to innovate and deliver with precision, the integration of 3D printing and advanced digital manufacturing into aerospace workflows is emerging as a true game-changer. MatterHackers stands at the forefront of this transformation, offering tailored solutions that solve real aerospace problems and give engineering teams back control and confidence.

What Aerospace Needs: Solutions, Not Just Tools

  • Agility: Rapid iteration and the ability to adapt designs in-house, without blowing up timelines or budgets.
  • Material Excellence: Access to aerospace-grade materials that deliver on strength, weight, and compliance.
  • Collaboration: Platforms and workflows that keep engineering, procurement, and production in sync.
  • Speed: Tools that turn weeks of waiting into hours of progress.

Reliability: Processes and machines that deliver quality and compliance, every single time.

Why Aerospace Relies on MatterHackers

We chose MatterHackers as our digital manufacturing partner because they understand these challenges—not just in theory, but in practice. Here’s how MatterHackers helps aerospace teams overcome their biggest obstacles and stay ahead in a demanding industry:

1. Rapid, Flexible Tooling—No More Waiting

With MatterHackers’ advanced 3D printing lineup, including the industrial Meltio M600 metal 3D printer, large-format BigRep ONE, and the high-precision Markforged Onyx Pro, aerospace teams can produce custom jigs, fixtures, and tooling on demand. Need a new fixture or a custom assembly aid? Print it in-house with engineering-grade precision—often in hours, not weeks. This means less downtime, more control over schedules, and the ability to rapidly iterate as requirements evolve.

Featured Products:

  • Meltio M600: Metal 3D printing for true aerospace-grade tooling and end-use parts.
  • BigRep ONE: Massive build volume for large tooling and composite layup molds.
  • Markforged Onyx Pro: Carbon fiber-reinforced parts for lightweight, ultra-strong fixtures.

2. Aerospace-Grade Materials, Ready When You Are

MatterHackers keeps aerospace innovators supplied with the latest high-performance materials—composites, metals, and advanced polymers—all engineered for the rigors of flight. Our NylonX Carbon Fiber PA12 filament, for example, delivers exceptional strength-to-weight ratio, chemical resistance, and thermal stability, making it ideal for functional prototypes and flight-ready components. Need to print in PEEK, PEI, or custom alloys? Our team helps you match the right material to your exact requirements, ensuring compliance and performance.

Featured Materials:

  • NylonX Carbon Fiber PA12: Superior mechanical properties for demanding aerospace applications.
  • PRO Series ABS & PETG: Trusted for robust, consistent prototyping and production.
  • Metal Filaments & Resins: For high-temperature, high-strength, and certified end-use parts.

3. Seamless Collaboration Across the Supply Chain

Digital manufacturing only works when everyone is on the same page. MatterHackers’ MatterControl software and digital solutions make it easy to share designs, gather feedback, and track changes in real time. Engineering, procurement, and production teams stay aligned—reducing miscommunication, avoiding costly rework, and ensuring a smoother path from concept to flight.

Featured Solutions:

  • MatterControl Software: Centralized design management, version tracking, and print scheduling.
  • Cloud-enabled Platforms: Secure, collaborative workflows for distributed teams.

4. Prototyping and Production, Accelerated

With printers like the UltiMaker S5 Pro Bundle and Formlabs Form 3L, aerospace teams can iterate and validate tooling and component designs rapidly—reducing project risk and accelerating timelines. These systems are built for fast prototyping and reliable end-use production, giving engineers the freedom to innovate without delay.

Featured Printers:

  • UltiMaker S5 Pro Bundle: Dual extrusion, large build volume, and material handling for continuous production.
  • Formlabs Form 3L: Large-format resin printing for smooth, accurate prototypes and functional parts.

5. Automation and Precision, Built In

Many MatterHackers systems offer automation features that reduce manual labor and eliminate human error. From automated filament handling on the BCN3D Epsilon W50 Smart Cabinet to the precision of CNC routers like the Carbide 3D Shapeoko 5 Pro, you get repeatable, high-precision results—every time.

Featured Automation:

6. Expert Support, Every Step of the Way

You’re never left guessing. MatterHackers’ solutions team partners with you from day one, offering guidance on materials, machine selection, process optimization, and compliance. Our experts help you navigate regulatory requirements, material certifications, and quality assurance—so you can deliver results that keep stakeholders confident.

The Result: Confidence, Control, and a Competitive Edge

With MatterHackers as your digital manufacturing partner, you’re not just keeping up—you’re leading. You deliver faster, adapt to change with ease, and meet the highest standards of quality and compliance. Your teams are more aligned, your budgets are under control, and your stakeholders trust you to deliver—every time.

Ready to Take Control of Your Aerospace Tooling?

If you’re ready to eliminate uncertainty and unlock new levels of agility, it’s time to talk to MatterHackers. Schedule a consultation with our aerospace solutions team and discover how digital manufacturing can transform your tooling process—and your business.

Schedule your consultation today and experience the MatterHackers difference.

MatterHackers: Empowering Aerospace with Agility, Precision, and Innovation.