Custom 3D Printing for Aviation MRO

We offer several solutions tailored specifically for MRO operations:

• Component-specific shipping covers - Custom designed for servo valves, fuel nozzles, fuel pumps, manifolds, fuel controls (HMU, MEC, FMU, Etc.), blades and vanes, and other critical parts
• Work-in-progress protective covers - Branded covers for components during the repair process, or for shipping to your customer afterwards.
• Specialized tooling and jigs - Custom tools for specific maintenance procedures. Shadowboxes, teardown trays, disassembly jigs and fixtures, etc.
• Organizational systems - Part tracking and workflow management solutions
• Testing fixtures - Component-specific testing apparatus

Each solution is designed to the exact specifications of your components and workflow, with your company branding integrated throughout.

For AOG (Aircraft On Ground) situations, we offer expedited production and shipping:

• Standard turnaround: 48 hours from design approval to shipping
• AOG expedited service: 24-hour production on pre-approved designs
• Emergency design services: Same-day design for critical components

We maintain digital design files for all previous projects, allowing us to quickly reproduce or modify existing solutions for faster turnaround in urgent situations. We also offer worldwide expedited shipping through our logistics partners.

Our Bambu X1-C printers support a wide range of materials, which we select based on the specific requirements of each application:

• PLA (Polylactic Acid) - Excellent surface finish for non-structural components and prototypes, ideal for cosmetic parts with company branding
• ABS (Acrylonitrile Butadiene Styrene) - High impact resistance and heat tolerance, perfect for functional shipping enclosures and tooling
• PETG (Polyethylene Terephthalate Glycol) - Chemical-resistant with good clarity, excellent for inspection windows and protective covers
• TPU (Thermoplastic Polyurethane) - Flexible material for shock-absorbing components, custom gaskets, and vibration dampening
• PA-CF (Carbon Fiber Nylon) - Exceptional strength-to-weight ratio for high-performance tools and fixtures requiring stiffness
• ASA (Acrylonitrile Styrene Acrylate) - UV-resistant alternative to ABS for outdoor applications or components with sun exposure
• PC (Polycarbonate) - Extremely durable with high heat resistance for demanding mechanical applications

All materials are selected based on their suitability for aviation applications and compliance with relevant standards.

Our premium shipping solutions elevate your brand presence in several important ways:

• Professional presentation - Custom-branded solutions showcase your attention to detail and commitment to quality at every touchpoint
• Customer perception - Recipients immediately recognize the care and precision that extends from your repair services to your packaging
• Market differentiation - Stand out from competitors who use generic packaging with tailored solutions that reflect your technical expertise
• Service continuity - Maintain the premium quality experience from repair process through delivery

MRO shops using our premium shipping solutions report significant improvements in customer experience ratings and increased referral business from impressed clients.

Yes, we offer comprehensive reverse engineering services to recreate and improve upon existing OEM shipping containers:

• Similar dimensions and functionality - We can create solutions with measurements comparable to your existing containers, often with improved protective features
• Material adaptation - While original containers might be metal or other materials, our 3D printed alternatives offer similar or superior protection while reducing weight and cost
• Brand incorporation - Unlike generic OEM containers, our reverse-engineered solutions include your company branding
• Functional improvements - We often identify and implement improvements to the original design, such as better grip points, clearer labeling, or enhanced shock protection

Simply send us your existing containers, and our engineering team will handle the analysis, design, and production of your custom solution. All designs remain exclusive to TurbineWorks to ensure quality control and consistent manufacturing standards.

Absolutely! We welcome client-provided design files and offer comprehensive services to turn your designs into finished products:

• Compatible file formats - We accept industry-standard formats including STL, STEP, OBJ, and most CAD file types
• Design review and optimization - Our engineering team will review your designs and suggest optimizations for FDM printing if needed
• Prototyping - We can produce prototypes for testing and validation before committing to full production
• Production scaling - Once your design is finalized, we can produce quantities from one-off pieces to large production runs
• Material selection guidance - We'll help you select the optimal material based on your application's requirements

If you have a file format not listed here, please contact us—we can often accommodate additional formats or convert your files to a compatible format. For optimal results, we recommend STL or STEP files with the highest resolution possible.

We believe in a truly collaborative approach to ensure the perfect solution for your needs:

• Send us your parts - You can ship physical components directly to us for detailed measurement, analysis, and evaluation
• Interactive design reviews - Regular communication through your preferred channel (email, calls, or video conferences) to review designs and make real-time adjustments
• Engineering collaboration - Our technical team works directly with your engineers or maintenance staff to understand specific requirements and constraints
• Iterative prototyping - We can develop multiple prototype versions with progressive refinements based on your feedback and testing
• On-site evaluation support - For complex projects, we can arrange for on-site meetings to better understand your facility's specific needs
• IP ownership clarity - Designs we create through this collaborative process remain TurbineWorks' intellectual property, with customers receiving a license to use the manufactured products

This collaborative back-and-forth ensures that the final product precisely meets your requirements. We're not just a vendor; we're an extension of your team focused on delivering solutions that work perfectly in your specific environment.

We accept a wide range of 3D model file formats to accommodate different design workflows:

• Standard 3D printing formats: STL (.stl), OBJ (.obj), 3MF (.3mf)
• CAD formats: STEP (.step, .stp), IGES (.iges, .igs), Solidworks (.sldprt, .sldasm), Autodesk Inventor (.ipt, .iam), Fusion 360 exports
• 2D drawings: PDF, DXF, or technical drawings that our team can convert to 3D models
• Archive formats: ZIP files containing multiple related models or complex assemblies

If you have a file format not listed here, please contact us—we can often accommodate additional formats or convert your files to a compatible format. For optimal results, we recommend STL or STEP files with the highest resolution possible.

We take intellectual property protection and confidentiality extremely seriously:

• Clear ownership boundaries: Any designs created by TurbineWorks, including reverse-engineered designs based on customer parts, are our intellectual property. Designs directly provided by customers remain 100% the customer's property and are treated as proprietary
• Confidentiality agreements: We're happy to sign NDAs before receiving your designs or models
• Secure file handling: All digital files are stored in encrypted systems with restricted access
• Limited-access production: Only authorized personnel have access to client designs and models
• No design redistribution: Your designs are never shared with third parties or other clients
• Secure disposal: Digital files can be permanently deleted upon project completion if requested

We protect your confidential information and respect the intellectual property rights of designs you directly provide to us. When we reverse-engineer or create new designs based on your parts or requirements, those designs remain TurbineWorks' intellectual property, but you receive a license to use the manufactured products for your business needs.

Maintaining consistent quality across high-volume production is central to our manufacturing process:

• Standardized printer settings: We maintain detailed profiles for each material and application type
• Quality control protocol: Every part undergoes systematic inspection against established standards
• First article inspection: The first piece of any new production run is thoroughly validated before full production
• Statistical process control: We monitor key print parameters across production batches
• Regular calibration: All printers are calibrated on a strict schedule to ensure dimensional accuracy
• Material lot tracking: We track material batches to maintain consistency between production runs

For ongoing production needs, we can create a detailed specification document for your parts that ensures consistent quality over months or years of production. This includes archiving specific printer profiles dedicated to your jobs.

Our production facility is designed to handle a wide range of order volumes:

• Multiple printer farm: Our facility houses multiple high-performance FDM printers that can run 24/7
• Parallel production: We can run multiple parts simultaneously across our printer fleet
• Scalable capacity: We can quickly scale up capacity for urgent or large orders
• Just-in-time production: For ongoing needs, we can establish regular production schedules aligned with your operations
• Inventory management: For repeat orders, we can maintain stock of your most frequently used items

We've successfully handled production runs ranging from single prototypes to thousands of parts per month. Our team can work with you to develop a production schedule that meets your volume requirements and delivery timelines.

Absolutely! Our engineering team specializes in optimizing designs for FDM printing technology:

• Design review: We analyze your models for potential printing challenges before production
• Wall thickness optimization: We ensure walls are thick enough for durability but not wasteful of material
• Support structure minimization: We orient parts and adjust geometries to reduce support material requirements
• Assembly optimization: For multi-part designs, we can suggest improvements for fit and function
• Material-specific adjustments: We optimize tolerances and features based on the selected material's properties
• Cost reduction: We can suggest design changes that maintain functionality while reducing printing time and material usage

Our goal is to ensure your designs not only print correctly but also perform optimally in their intended application. We'll provide feedback and suggestions while respecting your design intent and functional requirements.

Many of our clients maintain some in-house printing capability but partner with us for specific advantages:

• No capital investment: Avoid the high costs of purchasing and maintaining industrial-grade 3D printers
• Expertise on demand: Access our specialized knowledge in aviation-specific applications without maintaining specialized staff
• Scalable capacity: Handle volume spikes without investing in equipment that might sit idle during slower periods
• Faster turnaround for complex jobs: Our optimized workflows and dedicated equipment can often produce complex parts faster than general-purpose in-house setups
• Material versatility: Access a wide range of materials without purchasing and storing multiple filament types
• Quality assurance: Our standardized quality control processes ensure consistent results for critical components
• Focus on core operations: Concentrate your team's efforts on your core MRO activities rather than managing 3D printing operations

Many clients use a hybrid approach—handling simple, one-off prints in-house while outsourcing complex designs, large volumes, or production runs that require consistent quality over time to us.