Markforged 3D Printers Creating Luxury Aircraft Parts For Cabin Management Solutions

Texas-based aviation company Cabin Management Solutions (CMS) has enlisted The Digital Forge—an industrial platform of 3D printers, software, and materials from Markforged that enables manufacturers to print parts at the point-of-need. Founded in 2019, CMS works with aircraft maintenance, repair, and overhaul companies and individual aircraft owners to design cabin control and entertainment systems for luxury, private, and business aircraft. CMS plans to continue deploying Markforged’s additive manufacturing solutions, particularly Markforged’s Onyx™ FR-A and Carbon Fiber FR-A—aerospace-ready versions of Markforged’s Onyx FR and Carbon Fiber FR materials.

Thanks to Markforged’s X7 carbon fiber 3D printers, CMS is able to manufacture industrial-grade parts in hours instead of weeks. “In the aerospace industry, quality and on-the-fly adaptability are crucial to success,” said Jeff Pike, VP of Engineering at CMS. “We often have to produce low-volume, high-value parts from scratch which can be time- and labor-intensive. Markforged’s X7 allows us to do this quickly and more efficiently while ensuring functionality and retaining the upscale aesthetics expected in luxury aircraft.”

Cabin Management Solutions 3D printed light switch panels, latches, and electronic accessories.

Continuous Carbon Fiber-Reinforced Aircraft Parts

The X7 3D prints with continuous carbon fiber reinforced parts that can be as strong as machined aluminum, making the material an excellent alternative. Carbon fiber filament is already a strong filament. However, to obtain an even stronger part, continuous carbon fiber reinforcement is used. Furthermore, continuous carbon fiber 3D printing is strong enough to replace aluminum at half the weight. In fact, it is possible to add even more strength to a part while also reducing material use when 3D printing with continuous carbon fiber.

CMS uses Markforged’s Onyx™ FR 3D printer to produce high-strength, low-weight, flame-retardant, and FAA-compliant custom aircraft parts—by using Markforged’s X7 printers, CMS is now capable of completing higher volume jobs plus the company has been able to improve the quality and delivery times while successfully undergoing a rigorous testing and certification process. With the X7 printer, the CMS team printed at least 100 different parts for one aircraft, including nearly 20 light switch panels, a cabin climate controller, latches, release buttons, USB-C and drop-in USB-A chargers, and adjustable touch screen brackets—all with luxury end-use aesthetics. Learn more about Cabin Management Solutions’ use of Markforged’s technologies HERE.

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