It is no secret that when aircraft undergo scheduled maintenance cycles, including major “C” and “D” checks that can last from six weeks to a year, operators often face challenges sourcing replacement parts for legacy systems, which can take aircraft out of service for months.
To address this, Spectrum Networks, LLC has adopted Markforged’s FX10 platform and Continuous Fiber Reinforcement (CFR) technology to design and manufacture replacement lighting and interior parts in a matter of weeks instead of months.
Spectrum aims to transform the aviation industry by enhancing passenger experience and safety through technologies. ALOFT AeroArchitects, a completion and maintenance provider for VIP and special mission aircraft, installed the precision-engineered components on the exclusive aircraft.
“Our customers expect absolute reliability. These aren’t just private jets; they’re aircraft transporting world leaders and governments,” said Colby Hall, Director of Technology at ALOFT AeroArchitects. “Markforged’s technology allows us to receive parts with unmatched precision and traceability while cutting lead times from up to six months to just a few weeks.”
The SPN 31 LED retrofit
Originally developed to replace outdated halogen fixtures on 20-year-old aircraft panels, Spectrum Networks’ SPN 31 LED retrofit was engineered using Markforged’s Continuous Fiber Reinforcement (CFR) technology to achieve superior structural integrity and a surface finish suitable for direct installation.
“You’re able to pull the part right off the machine and ship it out the door, as is. With Continuous Fiber Reinforcement, we noticed quickly that it gives us structural properties that we never thought were possible,” said Niel Gunnarson, President and COO of Spectrum Networks, LLC. “Our customers are able to use that information and propose designs that they need using those benefits.”
Just like the 10,000+ certified flight parts already produced with Markforged 3D printers, this part underwent automated laser micrometer inspection, generating a layer-by-layer conformance report.
This accelerates regulatory acceptance within the FAA and global aviation authorities and shows added value for additively manufactured parts for aerospace and aviation.
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