The Future of Aviation is Lightweight and Integrated
In aerospace, every gram saved translates directly into increased payload, extended range, and reduced carbon emissions. At Prototal, we provide the certified infrastructure to move beyond the limitations of subtractive machining and heavy assemblies.
By leveraging certified workflows, we enable the production of high-complexity ducting, structural brackets, and interior components that are topologically optimized for maximum performance and minimum mass.
AS/EN 9100 | ISO 9001 | ISO 14001 | Cleanroom ISO 8
We are a strategic extension of your supply chain.
My goal is to help the aerospace & defense industry bridge the gap between legacy requirements and future possibilities. By embracing certified, smart manufacturing workflows, we help our partners iterate faster, scale seamlessly, and ensure that their technology remains at the cutting edge. We are building the infrastructure for the next generation of aerospace & defense.
— Karin Holst, Global Sales Director for Aerospace & Defense at Prototal Group
Why Choose Prototal for Aerospace?
We provide a seamless transition from rapid aerodynamic prototyping to certified serial production, ensuring your components meet the most stringent safety and quality benchmarks in the sky.
High-Performance Polymers & Certified Traceability
Aerospace applications demand materials that offer extreme flame retardancy, low smoke toxicity (FST), and high heat deflection. We utilize industry-standard polymers such as PA 12 and specialized composites that provide the rigidity of metal at a fraction of the weight. Every part produced for flight can be provided with full material traceability and process documentation, meeting the rigorous standards required by global aviation authorities.
Extreme Part Consolidation & Weight Reduction
Traditional aerospace assemblies are often comprised of dozens of machined parts, rivets, and fasteners, each adding weight and potential failure points. Additive Manufacturing allows you to consolidate these complex assemblies into a single, monolithic structure. By integrating functional snap-fits and internal mounting features directly into the design, you can eliminate the mass of traditional hardware and reduce assembly labor, resulting in a stiffer, lighter, and more reliable component.
Conformal Ducting & Environmental Control Systems (ECS)
Traditional ducting is restricted by the limitations of bending and welding, often resulting in suboptimal airflow and wasted space. with Industrial 3D Printing you can design and print conformal ducting with complex internal geometries that follow the exact contours of the airframe. This optimizes fluid dynamics, reduces turbulence, and allows for the integration of mounting points directly onto the duct skin, saving critical space in cramped avionics bays.
Digital Inventory & Rapid MRO Support
AOG (Aircraft on Ground) situations are incredibly costly. Managing a global physical inventory of legacy cabin parts or specialized tools is a massive logistical burden. We enable a Digital Supply Chain for MRO (Maintenance, Repair, and Overhaul). By storing parts as digital twins, we can print replacement cabin components or ground support equipment on-demand. This ensures that legacy fleets remain operational without the need for massive warehouses of “just-in-case” inventory.
Vapor Smoothing for Aerodynamic & Fluid Efficiency
For external components or internal fluid-handling parts, surface friction is a critical variable. Prototal utilize Vapor Smoothing to seal the surface of 3D printed polymers. This creates a gas-tight finish that improves aerodynamic flow and prevents moisture ingress, ensuring the structural integrity of the part remains uncompromised throughout thousands of flight cycles.
The New Standard of Precision
Leveraging our calibrated HP Multi Jet Fusion (MJF) technology, we push the boundaries of what’s possible in advanced hardware design. With the ability to produce high-density PA 11 components featuring hole diameters as low as 0.4 mm, we enable the production of advanced filtration systems and cooling manifolds that ensure operational readiness in the harshest environments.
Strategic Partners in Flight-Ready Innovation
Prototal operates as a strategic extension of your engineering team, providing the manufacturing continuity required for both high-velocity aerospace innovation and long-term fleet sustainment. We bridge the gap between advanced aerodynamic design and certified serial production, leveraging a deep understanding of the rigorous regulatory and safety standards mandated by global aviation authorities.
As a certified partner of leading OEMs like HP and EOS combined with our AS/EN 9100 certification, we provide the validated repeatability necessary for mission-critical hardware.
Aerial Case Studies
CODRONE
CODRONE partnered with Prototal to bring its first commercial product, an AI powered surveillance drone, to market from prototype to production.
Windracers
Prototal partnered with Windracers, a UK-based aerospace company, to support the development and production of lightweight polymer components for a long-range, heavy-lift cargo drone.
Manufacturing Services for Defense
Quote Your Next Project
Looking for high-quality industrial 3D printing or injection molding solutions tailored to your needs? Our team is ready to provide a detailed quote for your project. Simply share your specifications, and we’ll deliver a clear, competitive estimate — no surprises, just precision and reliability.
Why choose us?
- Industrial 3D printing, injection molding and vacuum casting solutions for any scale and complexity
- Fast and accurate quoting process
- Local presence close to your business and business needs
Bring Your Design to Life
"*" indicates required fields
By submitting this form, you agree to our Privacy Policy. We use the information you provide to respond to your inquiry and provide requested manufacturing services.
FAQs
Whether you are navigating the transition from prototyping to serial production or optimizing an existing supply chain, we are here to provide the technical clarity you need. If your specific challenge isn’t covered here, our application engineers are ready to discuss your project’s unique requirements and help you find the most efficient path to production.
AS/EN 9100 is the bedrock of our aerospace operations. It ensures that every step of the manufacturing process, from initial file intake and material handling to the final 3D printing and inspection, is governed by a rigorous Quality Management System. We provide comprehensive reports and full batch traceability, giving you the documentation required for airworthiness certification.
We treat all defense projects with the highest level of discretion. Our facilities follow strict protocols regarding data handling and encryption. We are prepared to work within the specific security frameworks or non-disclosure agreements (NDAs) required by government contractors and national security agencies.
In many applications, yes. By utilizing topological optimization, we can design polymer brackets that mimic the stiffness of aluminum while significantly reducing weight. While metal remains necessary for high-load primary structures, our high-performance polymers are increasingly used for secondary structures, avionics mounts, and interior fittings where weight-saving is the primary driver.
For specialized aircraft or limited-run projects, traditional injection molding tooling is often too expensive and slow. Our ability to scale 3D printing to 100,000 parts allows OEMs to move straight from design to serial production. This “tool-less” approach enables design iterations late in the development cycle and ensures that you only produce the exact volume required, eliminating the risk of obsolete inventory.
A reoccurring challenges is maintaining platforms that have been in service for decades. If an original manufacturer no longer exists, we can reverse-engineer the component and 3D print a replacement. This “On-Demand” production prevents the grounding of expensive assets due to a single missing bracket or housing.
Our UK facility is our primary center of excellence for aerospace and defense manufacturing, holding full AS/EN 9100 certification. This accreditation ensures that our UK-based industrial 3D printing and engineering workflows meet the rigorous requirements demanded by the global aviation and defense industries. By centralizing our aerospace expertise here, we provide a localized, high-compliance hub for European and international OEMs requiring flight-certified components with full batch traceability.
