Advanced Additive Manufacturing Services For Aerospace & Defense
We deliver AM engineering services and precision-engineered AM solutions for aerospace, defense, space, automotive, industrial, robotics, and medical programs. Production parts, customized parts, tooling and rapid prototyping, engineered to the highest standards of quality and efficiency.
Trusted by leading engineering teams globally
Rapid prototyping, large-scale
production & custom parts.
Cutting-edge technology delivering precision-engineered solutions for aerospace, defense, automotive, industrial, robotics, medical & dental, and more, all under one AS9100D-controlled roof in Horsham, Pennsylvania.
Rapid Prototyping
FDM, SLA, and SLS prototypes turned in days, accelerate design iteration with functional and visual parts in your hands fast.
Production & Replacement Parts
On-demand serial production for flight hardware, HVAC, water systems, avionics covers, cable management, and legacy MRO parts.
Manufacturing Tools & Aids
Lightweight jigs, fixtures, end-of-arm tooling, and composite layup molds engineered to your production rate.
Aerospace-Grade Materials
14+ qualified materials including ESD-safe Antero, FAR 25.853 Ultem, PEEK, ESD-safe variants, and DMLS metals.
Engineering Design (DFAM)
3D scanning, reverse engineering, 2D-to-3D CAD conversion, and design-for-additive collaboration with your engineering team.
Large-Scale Production
Build envelopes up to 36″ × 24″ × 36″ with documented AS9100D process control, scaling from one-off parts to serial production runs.
Precision-engineered solutions for various industries.
From the most demanding aerospace programs to automotive R&D, robotic production cells, medical R&D, and one-off design studios, our shop scales to your service environment.
Polymers and alloys built for the mission envelope.
From ESD-safe ducting on next-gen avionics to autoclavable composite tooling and Ti-6Al-4V mounting hardware, every material is qualified, traceable, and ITAR controlled.
- MaterialAntero 800NAProfilePEKK · low-outgassingSpecFDM · Fortus
- MaterialAntero 840CN03ProfilePEKK · ESD-safeSpecFDM · Fortus
- MaterialVICTREX AM™ 200 PEEKProfilePAEK · high-tempSpecFDM · F450/F900
- MaterialUltem 9085ProfilePEI · FAR 25.853SpecFDM · Fortus
- MaterialUltem 1010ProfileAutoclavable · biocompatibleSpecFDM · Fortus
- MaterialNylon 12CFProfileCarbon fiber · structuralSpecFDM · Fortus
Stratasys Fortus 900, AIS/AICS qualified for Antero 800NA, 840CN03 & Victrex AM 200 PEEK.
Mission-grade ESD-safe, low-outgassing, and high-temperature polymer production for satellites, UAVs, and avionics chassis. Backed by Fortus 450, Fortus 370, Formlabs Fuse, Form 3B/3L, HP MJF, and EOS DMLS production cells.
Read technology briefLargest validated FDM envelope for serial aerospace production in the Northeast.
Closed-loop process control with in-line metrology and traceable lot ID.
Tackling obsolescence and supply chain challenges.
We understand the rising importance of maintaining and extending the life of your legacy assets. Our additive manufacturing technology and our Design & Engineering team are built to address obsolescence, supply-chain disruption, and unavailability of parts from original equipment manufacturers, keeping your hardware in service and minimizing downtime.
Obsolescence solved
Reverse-engineer parts the OEM no longer supports: laser scan, model, qualify, and print on demand.
Supply chain resilience
Domestic, single-source manufacturing eliminates exposure to offshore delays and Section 889 risk.
Print-on-demand spares
Eliminate warehouse cost and capital tied up in spare-parts inventory. Print what you need, when you need it.
AOG response
Same-day-quote, days-not-weeks delivery on grounded-aircraft and line-down replacement parts.
From quote to flight-ready in as little as 5 days.
- STEP / 01Submit RFQ
Upload your STEP, IGES, or 2D drawings through our secure portal. NDAs and ITAR pre-checks happen automatically.
- STEP / 02DFAM consult
Our engineers redesign parts for additive, optimizing for weight, lead time, and program-level cost.
- STEP / 03Validated build
Production on our AS9100D-controlled FDM, SLS, SLA, or DMLS lines with full traceability and lot history.
- STEP / 04Inspect & ship
Laser-scanned first-article reports, FAI documentation, and direct-to-line delivery on your program rate.
Hear from our loyal customers.
Engineering leaders across aerospace, automotive, and design studios trust AAM as an extension of their team.
“American Additive is our go-to partner for all things additive. We are grateful we met and will be working together for years to come.”
“My experience with AAM has been excellent. I highly value their ability to help us make decisions with our automotive engineering designs.”
“AAM was able to produce high-quality prints in fast turnaround time. Without their help, we wouldn't have completed our project on time.”
The latest from American Additive.
3D Printing with AIS™ Antero® 800NA and 840CN03 Materials on the Stratasys Fortus 900
Read more
Meet AAM at AeroDef | RAPID + TCT 2026 - Booth #2209, Boston, MA
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AAM at Verticon 2026 - Booth #B9510, Georgia World Congress Center
Read moreAccelerate product
development.
Transform your ideas into reality and elevate your designs to the next level. Don’t wait. Unleash your creativity and experience unparalleled precision today. Drawings, sketches, or a paragraph of intent. We quote within 4 hours.