Flight Control Joystick

3D Printing Process

At iamrapid, we leverage SLS (Selective Laser Sintering), MJF (Multi Jet Fusion), DMLS (Direct Metal Laser Sintering), and SLA (Stereolithography) 3D printing technologies to meet the stringent aerospace industry requirements. These additive manufacturing methods offer unique advantages, making them suitable for prototyping, functional testing, and end-use applications.

Technology Breakdown & Advantages

1. SLA (Stereolithography) – High-Precision Prototyping

• It uses a precision laser to cure liquid resin, offering an exceptional surface finish and fine details.
• Ideal for high-accuracy prototypes, ergonomic parts, and aerodynamic surfaces.
• Great for cockpit controls, flight grips, and intricate cabin components requiring aesthetic refinement.

2. SLS (Selective Laser Sintering) – High-Strength Functional Prototypes

• It uses a high-powered laser to fuse nylon-based powders layer by layer.
• It is ideal for functional aerospace components due to its high strength, durability, and heat & chemical resistance.
• There is no need for support structures, allowing for complex geometries and lightweight lattice structures.

3. MJF (Multi Jet Fusion) – Production-Grade Strength & Detail

• It employs a fine powder fusion process with detailing agents for high mechanical performance.
• It produces dense, durable, and isotropic parts, making it great for aerospace housings and enclosures. Its surface finish is better than SLS.
• Faster production speeds and excellent repeatability are suitable for batch manufacturing aerospace parts.

4. Direct Metal Laser Sintering (DMLS) – Aerospace-Grade Metal Parts

• It uses a high-powered laser to sinter metal powders, layer by layer, into fully dense, high-strength metal parts.
• Capable of manufacturing titanium, aluminum, stainless steel, and Inconel components. It is strong and heat resistant.
• Perfect for engine brackets, heat exchangers, and other high-stress aerospace components requiring exceptional strength-to-weight ratios.

For this case study, we have chosen the SLA 3D printing process to showcase our prototyping capabilities in aerospace. SLA enables us to achieve exceptional detail, smooth surface finishes, and high accuracy, making it ideal for developing ergonomic and visually refined components like the flight joystick/controller.

Manufacturing Process

1. Pre-Processing & Preparation

• 3D model optimization for additive manufacturing
• Orientation and support generation to ensure a flawless print
• Selection of high-performance resin materials for durability and aesthetics. We have chosen ABS Resin for this particular component

2. SLA 3D Printing

• Layer-by-layer photopolymerization, using a high-precision laser to cure liquid resin
• Ensuring fine detailing in buttons, triggers, and grip surfaces for optimal ergonomics
• Achieving a lightweight yet structurally robust prototype

3. Post-Processing & Refinement

• Cleaning & UV curing to enhance part strength
• Light sanding & polishing for a premium aerospace-grade finish
• Optional painting or surface coating to replicate final product aesthetics

4. Assembly

• Fitting & Testing: Ensuring the parts assembled seamlessly with precision

By leveraging SLA 3D printing, we successfully demonstrate our ability to rapidly prototype aerospace-grade components with superior accuracy and design fidelity, reinforcing iamrapid’s expertise in aerospace additive manufacturing.

Final Showcase

The completed flight joystick demonstrates our ability to manufacture intricate aerospace components with high precision. The combination of advanced 3D printing techniques, optimized material selection, and detailed post-processing ensures a functional and visually refined product.