Customized space, aerospace & defense additive manufacturing
Customers choose American Additive for all of their production parts, rapid 3D printed tooling, and prototyping needs. We engineer and produce mission-grade 3D printed parts for aircraft interiors, ducting, electronics enclosures, structural hardware, and composite layup tooling, all under one AS9100D-controlled roof in Horsham, Pennsylvania.
Rapidly produce production parts. Tackle obsolescence and supply chain challenges. Eliminate downtime and reduce inventory costs. Speed up development with rapid prototyping. Minimize expenses by eliminating molds and tooling. Customize and personalize every project. Collaborate with our engineering team. Easily adapt to fluctuating demand with scalable production.
We are proudly located in the United States, catering to businesses seeking to onshore or reshore their operations and support the Made in USA initiative. Partnering with us means rapid delivery, expertise in design for additive manufacturing, and swift iterations on design changes, keeping your operations efficient, agile, and responsive.
Built for demanding programs.
Customized surrogate parts that replicate original geometry for training and maintenance confirmation while awaiting long lead-time flight hardware.
Ducting, cable guides, lighting bezels, and avionics covers in FAR 25.853 aerospace-grade polymers, AIS (AICS) qualified on the Fortus 900.
Topology-optimized structural brackets and mounts in Ultem, PEEK, Antero, and DMLS aluminum.
Antero 800NA and 840CN03 enclosures for avionics, radar, and radiation-sensitive systems.
Autoclavable Ultem 1010, PC, and Ultem 9085 layup tools, sacrificial mandrels, and trim fixtures for carbon-fiber programs.
Reverse-engineered legacy and obsolete components printed on demand, eliminating obsolescence and supply-chain risk.
Iterate designs and validate concepts fast, from concept-grade SLA to flight-grade FDM prototypes ready for environmental testing.
High-tolerance SLA and SLS test articles for aerodynamic and structural validation.
Lightweight airframe components, payload housings, and structural brackets for Group 2–5 unmanned platforms.
Built on the same AS9100D infrastructure.
High-performance thermoplastic parts in Ultem, PEEK, and Antero on production-grade Stratasys systems.
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Mirror-grade surface finish, micron tolerances, and a deep library of resins, for visual prototypes, wind-tunnel models, medical R&D, and master patterns.
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Aluminum, titanium, and Inconel hardware for thermal, structural, and propulsion applications: production-grade metal additive with HIP and machined finishing.
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End-to-end engineering support: meaningful customer interaction, DFAM, topology optimization, laser scanning, and obsolete-part replication.
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AIS (AICS)-certified cabin hardware in flame-retardant aerospace polymers: ducting, bezels, stowage, galley parts, and operator-interface components from one-off VIP installs to fleet retrofits.
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Autoclavable Ultem 1010, Ultem 9085, and polycarbonate layup and trim tools, engineered for efficient, reliable composite manufacturing.
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AIS (AICS)-certified cabin hardware and ESD-safe avionics for the world's commercial fleets.
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Business aviation, private aircraft, and experimental homebuilt programs — cabin parts, replacement hardware, and builder-grade components.
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On-demand replacement parts for fleets in service beyond OEM support.
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Lightweight structures and payload housings for U.S. military UAS Group 2–5 platforms.
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Low-outgassing, radiation-tolerant components for satellites, launch vehicles, and crewed systems.
ExploreThe printing technology behind this work.
Production-grade thermoplastic printing: the workhorse of aerospace additive manufacturing.
Photopolymer printing for mirror-grade surface finish and tight tolerances.
Production-grade metal additive in aluminum, titanium, and Inconel.
Validated aerospace-grade materials.
PEKK-based thermoplastic for avionics, low-outgassing space hardware, and high-chemical-resistance applications.
Carbon-nanotube reinforced PEKK with intrinsic ESD performance, engineered for mission-critical electronics.
High-performance PAEK (PEEK-family) formulated for additive: thermal-critical hardware up to 300°F continuous use.
The aerospace cabin standard: FAR 25.853 / OSU 65-65 compliant.
Higher heat and biocompatible: the choice for autoclave tooling and food-contact hardware.
Ready to take flight?
Let’s build hardware.
Send us your drawings, or just sketch on a napkin, and your program timeline. Our engineers will provide a rapid quote and deliver flight-ready parts built to your requirements and delivered on schedule.