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.”
“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 can go to any customer and let them choose the color and the print of the leather,” explains Henryk. “But even better are the options for the inserts. They can choose whether they’re separated or combined to allow space for a mobile phone, for example, or have their logo integrated into the design. That makes 3D printing very attractive — it would be impossible to balance the tooling costs with any other method.”
“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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