Home Applications & Case Studies Additive manufacturing in aerospace: How Stirling Dynamics has mastered the art of...

Additive manufacturing in aerospace: How Stirling Dynamics has mastered the art of application spotting

Stirling Dynamics is known for solving challenging problems with the help of additive manufacturing. Examples range from their unique seat blocker to the DADO panel repair kit and aircraft seat repair solutions. Learn how their approach to application discovery, market evaluation and testing is paving the way for the successful adoption of 3D printing.
As an EASA 21.J certified design organization, Stirling Dynamics has consistently delivered creative solutions for commercial aircraft. Their portfolio includes a wide range of components, from less critical cabin parts to complex electronic and avionic systems. Henryk Bork, Head of Aerospace at Stirling Dynamics, emphasizes the importance of passion in product development.

A crucial part of Stirling Dynamics’ success lies in the precise selection of the right materials and technologies for each task. One example of this approach is the DADO panel repair kit, which demonstrates how new solutions can be found by repairing rather than replacing.

“We developed this process for several reasons. Not everything becomes a 3D printing project, and we have to be very careful. Developing a part and bringing it up to an EASA Form-1 approval is a very time-consuming process for all involved,” says Henryk. “We first need to check whether 3D printing is applicable, then consider our internal policy of never copying a part.”

Another example of the innovative use of 3D printing is the seat blocker from Stirling Dynamics. Originally developed during the COVID-19 pandemic to save airline costs, the design was adapted after the pandemic for greater comfort.
“The product’s application changed when the pandemic ended. Now, our customers can offer extended comfort to their passengers by turning a row of three seats into two,” says Sergey Gettinger, Chief Design Engineer at Stirling Dynamics. “We worked on a new design, put it through the testing phase, and began manufacturing. The shape is roughly the same as the original, but we improved the inserts and the cupholders.”

“We are very much looking forward to collaborating with Materialise on metal printing for aerospace as well. It will be another game changer, and I have no lack of imagination,” Henryk answers. “It could be very interesting in terms of structural repairs and different solutions that don’t exist yet. Make no mistake, this requires time, research, development, and budget — but with Materialise and Proponent, we have the right partners to make it happen.”

With their unique approach and the right partners, Stirling Dynamics sees a promising future for 3D printing in aviation.

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