We worked with a Tier-1 aerospace supplier to redesign 14 complex brackets for additive manufacturing. The result: 60% shorter lead time, 35% weight reduction, and full AS9100 compliance.
When a Tier-1 aerospace supplier approached Kraftec with a challenge — 14 structural brackets that were consuming 6–8 weeks of machining lead time each — we saw an opportunity to demonstrate the true power of additive manufacturing in industrial applications.
“The DFM review alone identified 3 features that would have caused print failures. Kraftec’s engineers caught them before we wasted a single part.”
— Head of Engineering, Aerospace Client
The Challenge: Long Lead Times and High Tooling Costs
Traditional CNC machining of these aluminium brackets required 8–12 operations, specialized fixtures, and 6–8 weeks per batch of 50 parts. Any design change triggered a full re-tooling cycle costing €15,000–€40,000.
Our team proposed a hybrid approach: redesign the brackets using topology optimization for additive manufacturing (DMLS — Direct Metal Laser Sintering), then post-machine only the critical mating surfaces.
Results: 60% Faster, 35% Lighter
- Lead time reduced from 6–8 weeks to 2.5 weeks per batch
- Part weight reduced by 35% through topology optimization
- Zero non-conformances on first article inspection
- Full material traceability per AS9100D requirements
- Design iteration cost reduced from €40,000 to under €2,000