Build-to-Print Metal Additive Manufacturing
Certified execution of your part design - from powder to qualified part.
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Our EN9100-certified build-to-print service delivers engineered metal components with full process control, traceability, and unmatched material expertise.
Whether you're producing flight hardware, drivetrain components, or high-performance structures, we take full responsibility for the production process, including any special steps needed to meet your exact specifications.
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What You Can Expect:
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Materials: Ti-6Al-4V, Scalmalloy®, Inconel 718, AlSi10Mg
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Process: LPBF with validated parameters and qualified heat treatment
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Post-processing: Support removal, machining, coating, and NDT
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Traceability: Powder batch to final inspection
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Documentation: Full build reports, test data, and quality records
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We don’t just manufacture parts - we deliver finished, production-ready components that meet the highest functional and regulatory demands.
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Your design. Our certification. Delivered.
REQUIREMENTS CAPTURE
We begin by reviewing your specifications and translating them into a qualified manufacturing plan. Typically, we require:
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A 3D CAD model
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A technical drawing with tolerances
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Any material, process, or inspection requirements (e.g. NADCAP, ASTM, ISO)
If you don't have a finished design, we offer a Design & Build Service
PRODUCTION
We manufacture metal components using Laser Powder Bed Fusion (LPBF), primarily in titanium and aluminum alloys such as Ti-6Al-4V and Scalmalloy®. Our process is optimized for repeatability and quality, with full traceability and EN9100-certified controls.
For special materials or hybrid production workflows, we collaborate with trusted partners under our quality system.
QUALITY ASSURANCE
All parts are produced under EN9100-certified QA with material and process checks throughout.
QA scope includes:
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Dimensional verification
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Mechanical specimen testing
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Non-Destructive Testing (e.g. CT scan) on request
We provide full documentation: build reports, material traceability, inspection records, and more — so your parts are certifiable and production-ready.
REQUIREMENTS CAPTURE
A part’s function matters just as much as its form. To ensure we meet your performance and quality expectations, we ask you to share the most complete technical data you have available.
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The more clearly you define your requirements, the more effectively we can tailor the manufacturing approach, choose the right material, and ensure the end product is fully certifiable.
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What we need to get started:
Customer Data | Requirement | Preferred Format(s) |
|---|---|---|
3D CAD Model | Mandatory | STEP, STL, IGS, CATPart, CATIA V5, Fusion360 |
Technical Drawing | Optional | PDF |
Master Schedule | Optional | PDF, Excel |
PRODUCTION
Our Metal 3D Printing Production Workflow
Our standard manufacturing route uses Selective Laser Melting (SLM), followed by stress relief heat treatment, support removal, and surface finishing (fettling, blasting).
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If your technical drawings specify it, we can apply tailored post-processing steps to meet your part’s requirements.
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The table below shows typical tolerances and part characteristics achievable through SLM without additional finishing.
Values depend on material and geometry.
Key Product Characteristic | Ti6Al4V | Scalmalloy |
|---|---|---|
Surface Roughness (RA) (microns) | <10 | <10 |
Wall Thickness Tolerance (mm) | +/-0.2 | +/-0.2 |
General Profile Tolerance (mm) | +/-0.4 | +/-0.4 |
Minimum Local Wall Thickness (mm)* | 0.2 | 0.4 |
Maximum Part Size (x,y,z) (mm) | 400, 400, 350 | 410, 410, 520 |
Minimum Recommended Wall Thickness (mm) | 2.0 | 2.0 |
*This is the minimum possible thickness which might be possible depending on the specific part geometry and build orientation
POST PROCESSING
Most metal additive parts require post-processing to meet the functional and dimensional requirements of their final application.
We offer a range of post-processing capabilities, including:
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Precision machining (milling, turning, wire EDM) of key interfaces​
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Surface treatments for smoothing, corrosion resistance, or aesthetic finishes​
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Assembly services, including welding of multiple AM components
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Similar to casting, if post-processing is required then we will include machining stock in the printed part to allow for precise finishing.
Unusual specifications? We can tailor the process to your needs.
Get in touch with us to discuss your application.
QUALITY ASSURANCE
We apply rigorous process controls to ensure consistent, high-quality results across all parts produced. Our QA regime includes:
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Material verification through tensile testing of each batch
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Statistical process control of key parameters
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3D scanning of all parts to verify profile conformance
If tighter tolerances are defined in your technical drawing, we also offer:
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CMM inspection with detailed measurement reports
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Optional NDT services, including Liquid Penetrant Inspection and CT scanning for critical applications
Every part comes with a standard inspection package. For more advanced QA requirements, we tailor the inspection scope to your needs.
Quality Assurance Method | Standard / Optional | Purpose |
|---|---|---|
Tensile Specimens | Standard | Verifies Material Batch Quality |
Visual Inspection | Standard | Detects Surface Defects on Parts |
3D Scan | Standard | Confirms General Profile Accuracy |
CMM | Optional | Confirms Tight Tolerance Compliance |
Liquid Penetrant Inspection | Optional | Detects fine cracks in critical components |
CT Scan | Optional | Detailed internal inspection |