LFAM specialization caters to 3D printed composite tooling, molds

Additive Engineering Solutions (AES, Akron, Ohio, U.S.) supports the realm of large-format additive manufacturing (LFAM) services, specializing in industrial-scale 3D printing solutions. Established in 2016, AES distinguishes itself as a large global contract manufacturer offering extensive capabilities in both tooling and large-scale prototyping. Adoption of LFAM technology is capable of reducing schedule up to 50% and costs by 10-40% compared with more conventional 3D printing approaches.

This year, AES is showcasing several of its tooling examples, including a fuel tank mandrel and a CNC mill fixture. These LFAM tools are machined to global profile tolerances of ±0.010". AES uses a variety of polymers, including ABS, PETG, PC, PLA and PEI, all of which are reinforced with carbon or glass fiber.

At the core of AES’ offerings is its expertise in the design and fabrication of 3D printed tooling and molds, catering to diverse industries such as aerospace, defense, general aviation, marine and space. This includes layup (up to 400°F) and process tooling, forming and assembly tools, and even precast concrete tooling. Beyond tooling, AES excels in producing large-scale mock-ups, full-scale engineering mock-ups, marketing displays and assembly verification articles.

The company’s manufacturing prowess is underpinned by a wide array of technology, featuring multiple LFAM printers, complemented by equally large CNC mills. This combination enables comprehensive fabrication services, from initial 3D printing to precision postprocessing. AES has also expanded its capabilities with the adoption of robotic additive manufacturing systems, enabling the creation of more complex geometries and offering increased flexibility in production.

AES is committed to driving technological advancement and application development within the additive manufacturing industry. The company prioritizes delivering meaningful, problem-solving solutions to its customers, focusing on efficiency, precision and the ability to produce durable, high-quality components. AES also boasts AS9100 Quality Management System certification and compliance with NIST Cybersecurity standards, particularly crucial for its work in highly regulated sectors like aerospace and defense.