Why Aerospace & Defense Demand High-Performance Filaments

In aerospace and defense, parts must perform under extreme heat, vibration, and chemical exposure while meeting strict safety requirements. That’s why engineering polymers like PEEK, PEKK, Ultem™ (PEI), and carbon fiber-reinforced composites are preferred for aerospace 3D printing.

• Weight reduction: Replace metals to improve payload efficiency.
• Thermal stability: Continuous service above 150 °C (material dependent).
• Flame retardancy & compliance: Materials available that meet FST and UL94 V-0 requirements.
• Chemical resistance: Withstand jet fuel, hydraulic fluids, lubricants, and de-icers.

Top Materials for Flight-Ready Applications

PEEK (Polyether Ether Ketone)

PEEK filament combines a high strength-to-weight ratio with outstanding chemical resistance. It’s used for lightweight brackets, engine-bay components, and satellite housings.

• Typical Tg: ~143 °C; continuous use up to ~250 °C (application dependent).
• Excellent resistance to jet fuel and hydraulic fluids.

PEKK (Polyether Ketone Ketone)

PEKK filament offers similar thermal/chemical performance to PEEK with easier printability and smoother finishes (slower crystallization). Ideal for connectors, ducts, and dimensionally precise housings.

Ultem™ (Polyetherimide, PEI)

Ultem™ (PEI) is naturally flame-retardant and widely used for cabin interior components, electrical enclosures, and panels. Many grades support FST needs in aerospace.

Carbon Fiber-Reinforced Blends

Carbon fiber composites increase stiffness and heat deflection temperature while minimizing weight—perfect for UAV frames, instrument mounts, and tooling.

Printing Considerations

• High-temperature hardware: Nozzle >350 °C, bed up to 160 °C, actively heated chamber recommended for PEEK/PEKK/PEI.
• Moisture control: Dry filament before and during printing to avoid porosity and weak layer bonding. Check out our Filament Dryer and Filament Maintainer.
• Post-processing: Annealing can improve crystallinity for higher thermal stability and strength.
• Quality & traceability: For regulated environments, documentlot traceability, test data, and repeatable process parameters.

Real-World Aerospace & Defense Applications

• Cabin interiors: Ultem™ and PEKK for panels, air ducts, and seat components.
• UAV & drone structures: Carbon fiber composites for lightweight frames.
• Satellite components: PEEK/PEKK housings and brackets designed for thermal cycling.
• Custom tooling & fixtures: Heat-resistant jigs for MRO workflows.

How to Choose the Right Filament

1. Temperature envelope: Cabin vs. engine bay vs. near-space/orbital exposure.
2. Weight targets: Identify metal-to-polymer substitution opportunities.
3. Compliance needs: Validate FST / UL94 V-0 and any program-specific requirements.
4. Production plan: Prototype to end-use parts—ensure material availability and repeatable process windows.

Recommended Products

• PEEK Filament — maximum heat/chemical resistance for mission-critical parts.
• PEKK Filament — high performance with improved printability.
• Ultem™ (PEI) Filament — flame-retardant and FST-oriented interior solutions.
• Carbon Fiber Composites — stiffness and weight savings for structures and tooling.