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Nexair Avionics: Transforming Aircraft Maintenance with INTAMSYS and NeoMetrix

Discover how NeoMetrix and INTAMSYS collaborate to provide innovative 3D printing solutions for the aerospace industry, showcasing a project where a crucial aircraft glove compartment was successfully reverse-engineered and 3D printed.
DISCOVER 3D PRINTERS

NeoMetrix Technologies, Inc., an official reseller of INTAMSYS, specializes in advanced 3D technologies and solution-oriented approaches. Their expertise spans various industries, including aerospace, where they have established long-term relationships with major players like Lockheed, NASA, and Pratt Whitney.

 

The Challenge

Nexair Avionics needed to upgrade a Cirrus SR22 aircraft’s instrument panel, requiring a new glove box no longer available from the manufacturer. Traditional reverse engineering methods were time-consuming and prone to errors due to the complex geometry of aircraft parts.

 

The Solution

NeoMetrix employed the Creaform HandySCAN Black Elite to capture precise measurements of the existing glove box, creating a highly accurate STL file. This data was then processed using Geomagic Design X to produce a precise 3D CAD model. The redesigned part was printed using ABS material on the INTAMSYS FUNMAT HT, transforming the original multi-piece assembly into a single, 3D-printed component.

The 3D scanning technology enabled the rapid capture of the glove box’s shape, ensuring an accuracy of .001". The design was refined in Geomagic Design X, ensuring it matched the original part’s accuracy and design intent. The final ABS part was printed on the INTAMSYS FUNMAT HT, streamlining production and eliminating the need for expensive tooling.

Scan Data CAD Model
Scan Data CAD Model

The Result

We accompany our customers in a professional manner throughout the entire project - from planning and design to the prototype or the production of a complete series. Combining our 3D printing processes with conventional component processing, post-processing and surface refinement of the prototypes, small series or even a trade fair exhibit is our daily business. Since the company was founded in 1995, our experienced team in Gross-Gerau has made a name for itself well beyond the borders of the Rhine-Main area. We are one of the leading service providers for everything to do with 3D printing and have more than satisfied customers from a wide variety of industries - from the automotive and consumer goods industries to mechanical engineering and companies from the medical technology sector.

Alex Di Maglie
Managing Director,  4D Concepts

NeoMetrix's integration of 3D scanning and printing reduced the design cycles needed for fabricating the new part, achieving a perfect fit on the first attempt. The 3D printing process also enabled quick, cost-effective design changes without tooling costs, making it an ideal solution for the aerospace industry.

The application of high-end filaments made of high-performance plastics such as PEI is not new to the field of 3D Printing. However, it requires both, a wide range of skills (materials and production) and the appropriate machinery.

Thanks to its large-format 3D printer from INTAMSYS, 4D Concepts can now process a wide range of high-end plastics with excellent thermal and mechanical properties for prototyping. Parts are out of PEI 9085.
 

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The INTAMSYS FUNMAT PRO 410 has been a performant and reliable tool since day one. It allows us to process high-performance polymers that enable our customers to innovate with them in highly loaded, thermally challenging, and metal replacement applications. It gives us the confidence that is needed to print 24/7 unattended with long print jobs of 100+ hours. It redefines what can be achieved with FDM technology.

Fabio Trotti
3D R&D Manager, WEERG

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Our Solution

  • INTAMSYS FUNMAT PRO 410

    3D PRINTER

    FUNMAT PRO 410

  • 图片3

    COST-EFFECTIVE

    Print Larger, Print More

  • 4D-Concepts-0222-3-1024x938

    OPEN

    Open-Sourced Filaments

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