AIM3D, a pioneer in pellet-based 3D printing, has certified a new ExAM A 510 3D pellet printing solution specifically for aerospace applications, with a focus on ULTEM 9085.

AIM3D new ExAM A 510 3D pellet printing solution for aviation applications.

ULTEM 9085 component in the build chamber of an AIM3D ExAM A 510.

AIM3D offers the ExAM 255 and ExAM 510 3D printing systems with high build speeds, high quality, and superior cost efficiency. Together with AM-MRO GmbH, the ExAM 510 was extensively redesigned as the ExAM A 510.

A new benchmark for cost efficiency

Pellet-based 3D printing generally offers major advantages in unit costs. A 3D part made with commercially available pellets can achieve adequate mechanical properties comparable to injection molding.

Cost comparison showing the cost breakdown of 3D filament printing versus 3D pellet printing, using a ULTEM 9085 part as an example.

In addition to optimized unit costs and the highest quality, 3D printing offers other benefits to aerospace applications: on-demand production and decentralized manufacturing to provide spare parts promptly for the maintenance and servicing of machinery and equipment while limiting inventory.

3D pellet printing now opens up new possibilities for cost efficiency by reducing the unit costs of 3D parts in an otherwise equivalent process.

Key features of the new ExAM A 510

The focus was on ULTEM 9085, the high-performance polymer widely used in the aerospace industry. The new ExAM A 510 system had to demonstrate consistent tensile strength in ULTEM 9085 tensile specimens regardless of the machine or build position.

The certification process with AM-MRO combines high mechanical performance of the parts with maximum process stability of the 3D printing system. All process parameters are documented, standardized, and optimized during certification.

One result is a slightly higher density than that of filament-printed parts. The system modifications focused on highly uniform temperature distribution throughout the build chamber, as well as continuously controlled ULTEM 9085 material feeding in terms of temperature, dryness, and tamper protection.

Illustration of uniform temperature distribution in the build chamber of an ExAM A 510.

An important additional benefit was easier removal of support structures, reducing post-processing effort. The result is an ExAM A 510 with a build chamber actively heated on all sides. The large viewing window that is a distinctive feature of the standard ExAM 510 has been replaced by a camera for monitoring the build chamber—form follows function.

Certification partner AM-MRO

AIM3D’s ExAM A 510 and its ULTEM printing process were modified through a certification process with expert Stefan Roeding of AM-MRO GmbH in Germany. AM-MRO GmbH provides consulting, training, and auditing services to aerospace manufacturers in connection with the use of additive and other innovative manufacturing technologies.

As part of the certification process, AIM3D developed the ExAM A 510 and the printing process to meet the aerospace industry’s stringent requirements.

Potential for 3D pellet printing in aviation

3D filament printing also offer other opportunities for the aviation industry: material use and post-processing can be optimized, and part properties can be improved.

“Readiness for aviation with an ExAM A 510 combines substantial material cost advantages with part optimization. It also meets all requirements for decentralized, timely on-site manufacturing, from batches of one to medium-sized production runs, with high process stability and high part quality,” said Stefan Roeding, CEO of AM-MRO.

AIM3D highlights at Formnext 2026

At Formnext 2026, AIM3D’s 3D pellet printing for aviation applications will be the centerpiece of its exhibition, showcasing the ExAM A 510 system and aerospace components.

AIM3D will also focus on the high-performance material PEEK. Sample parts made from pure, medically certified PEEK and printed on an ExAM 510 will be on display, alongside other PEEK components.

Another development of interest for PEEK is a smaller ExAM with a smaller but heated build chamber, positioned below the ExAM 255. This system will be exhibited as a prototype and is still under development in Rostock. Rounding out the Rostock-based company’s presentation is the printing of extra-soft TPE (Shore 0) on an ExAM 255. Other TPE parts with a Shore hardness of 0 complete the display.