Advanced Prototyping and Production Solutions for the Aerospace Industry
At Malcolm Nicholls Ltd, we understand the critical demands of the aerospace sector. From rapid prototyping and design verification to the production of flight-ready components, our advanced manufacturing capabilities provide the precision, reliability, and material performance required for mission-critical applications.
Two of the UK’s largest 3D printers
Custom parts delivered in days
Ideal for low volume production and rapid prototyping
Get Your Quick & Easy Project Quote Today
The Role of Additive Manufacturing (AM) in Aerospace
Additive Manufacturing is transforming the aerospace industry by enabling the creation of lighter, stronger, and more cost-effective parts. We use a range of industrial 3D printing technologies to meet the sector’s most demanding challenges, from prototyping to the production of flight-ready components.
Weight Reduction
Our 3D printing processes create highly optimised, lightweight structures, this directly translates to lower fuel consumption and reduced CO2 emissions.
Functional Integration
We can consolidate multiple complex components into a single, unified part, which reduces assembly costs and eliminates the vulnerabilities of multi-part assemblies.
On-Demand Production
Our tool-free process allows for rapid iteration and supports on-demand manufacturing. This drastically reduces prototyping lead times and enables a just-in-time service for MRO (Maintenance, Repair, and Overhaul) operations and spare parts.
Cost-EffectivenessÂ
AM provides significant cost savings compared to conventional methods, especially for low-to-medium volume production runs.
Supply Chain Simplification
By consolidating parts and producing components on-demand, additive manufacturing streamlines the supply chain. This reduces reliance on multiple vendors and complex logistics, leading to improved efficiency and resilience.
Customisation and Innovation
The design freedom of AM enables the creation of complex geometries and customised parts that are impossible to produce with traditional methods. This allows for the development of exclusive innovations and part upgrades, driving continuous improvement and competitive advantage.
Get a Quote for 3D Parts
Getting a quote for your project is easy! Simply upload your 3D model file and receive a quote in minutes. We can also help with CAD drawings.
Fused Deposition Modelling (FDM)
FDM is a powerful solution for rapid iteration, functional prototypes, and end-use parts. We offer a range of FDM materials engineered for aerospace, including:
- ULTEMâ„¢ 9085 & PEKK/PEI: High-performance thermoplastics with exceptional FST (Flame, Smoke, and Toxicity) ratings and high thermal and chemical resistance, ideal for cabin interiors, ducting, and structural brackets.
- Carbon Fiber-Filled Composites: These materials enhance stiffness and strength-to-weight ratios, perfect for creating lightweight jigs, fixtures, and structural components.
Why Malcolm Nicholls?
UK Based
With headquarters in the Midlands, we can deliver your 3D parts nationally.
Years of Expertise
We are a family run business with decades of experience.
Finished to Perfection
A team of traditional model makers in house to give your 3D print the wow factor.
More Than Just 3D Printing
With our suite of machines and technology we also specialise in low-volume manufacturing, Vacuum Casting, CNC Machining and more.
Aerospace 3D Printing SLA, SLS & Vacuum Casting
This is a cost-effective method for producing high-fidelity, low-volume duplicates of master patterns. Our polyurethane resins can replicate a vast array of engineering plastics with properties such as high strength, heat resistance, and fire retardancy (UL94 V-0).
Selective Laser Sintering (SLS)
SLS produces strong, durable, and lightweight parts directly from powdered materials. It is ideal for end-use components like ventilation, ducting, and durable internal parts with complex geometries.
SLA is renowned for its exceptional surface finish, fine detail, and dimensional accuracy. We specialise in producing both large-frame and optically clear parts for wind tunnel models, fluid flow analysis, and optical systems.
Post Processing & Finishing
Post-processing your SLA is critical to get the most out of your 3d print. This multi-step process involves removing excess resin, curing the part for optimal strength, and potentially sanding and finishing for a desired aesthetic.
Depending on your desired outcome, we offer various finishing techniques, like painting or polishing, and we can personalise your creation for specific applications.
Advanced Applications & Services
- Low-Volume Production: For short runs of up to 1000 parts, our services offer a cost-effective alternative to injection molding, ensuring a smooth transition from prototype to production.
- Next-Generation Applications: We have the capability to support the development of next-generation projects, including 3D-printed rocket propulsion components and satellite parts, helping to reduce launch mass and improve orbital performance.
- Aerospace Models for Exhibitions: Our master model makers create highly detailed, visually stunning aerospace models for trade shows and displays.
- Testing & Verification: We provide critical support for the development process by producing precision-engineered parts for wind tunnel testing and design verification to help you identify and resolve issues early.
- From Prototyping to Production: We guide clients from initial design to certified end-use parts, adhering to the highest industry standards. We can provide documentation to support your certification and Design for Additive Manufacturing (DfAM) needs.
Trusted by Industry Leaders
We have experience creating exceptional 3D printed parts for leaders across various industries. From automotive and aerospace to point of sale and packaging, we can help.
Which 3D Printing Service do I need?
Learn more about the different options we offer.
SLA
Stereolithography (SLA) also often referred to as SLA is the most widely used resin 3D printing technology. it is generally considered to provide the greatest accuracy and best surface finish of any prototyping or 3D printing process.
SLS
SLS can build functional parts, casting patterns and tooling inserts from your 3D CAD data. Our HiQ Sinterstation system (SLS 3D Printing machine) represents the future of Instant Manufacturing Technology.
FDM
Manufacturing FDM known as fused deposition modelling is the most widely available form of 3d printing. It is an additive manufacturing technology that selectively deposits molten plastic to build parts layer by layer.
Our SLA Machines & Materials
We are home to two of the largest 3D printers in the UK! Our Neo 800 has an impressive 800 x 800 x 600m build capacity. Whereas most other stereolithography companies with SLA 3D Printing machines require large parts to be built in sections, we can build parts without the need for cutting. Therefore, parts are built quicker, finishing is streamlined and is cost-effective.
The materials we use for our SLA printing are Somos Watershed and Taurus.
Order 3D Printed Parts
Getting a quote for your 3D printing project has never been easier. We offer three straightforward options to meet your needs.
Option One – Perfect for those seeking a swift and hassle-free 3D printing quote.
Option Two – If your project requires more than just printing, option two is your go-to choice, where we can provide quotes for CNC machining, surface finishing, vacuum forming, and vacuum casting for your 3D parts.
Option Three – For large, complex, intricate, or multi-part projects, look no further than option three. Give us a call, and our team will be more than happy to assist you in bringing your vision to life.
At Malcolm Nicholls Ltd, we make quoting fast, easy, and simple.
CNC Machining in Aerospace
CNC machining is a cornerstone of the aerospace industry, known for its unmatched precision and repeatability. This subtractive process is critical for producing components that require tight tolerances and exceptional surface finishes, such as turbine blades, engine casings, and structural parts. We work with a wide array of high-performance materials, including titanium, aluminum alloys, and superalloys to meet the stringent quality and safety standards of the industry.
Get in touch
Address
Waterloo Industrial Estate, Waterloo Cres, Bidford-on-Avon, B50 4JH
Call Us
01789 490382
Email Us
quotes@mnl.co.uk