Caracol AM and Formes et Volumes Develop Large-Scale Aerospace Composite Tool

This article is based on an official press release from Caracol AM.

Italian Large Format Additive Manufacturing (LFAM) specialist Caracol AM has announced a strategic partnerships with French prototyping and mold manufacturer Formes et Volumes. According to the official company release, the collaboration successfully designed and manufactured a large-scale composite lamination tool specifically tailored for the aerospace sector. By leveraging advanced robotic 3D printing, the project aims to address the notoriously slow and complex tooling processes that have long challenged aerospace manufacturers.

The aerospace industry traditionally relies on multi-part assemblies and extensive CNC machining for composite lamination tooling. These conventional methods often result in long lead times, high production costs, and compounded tolerance risks. In response, Caracol AM and Formes et Volumes utilized Caracol’s proprietary Heron AM robotic platform to combine LFAM, fiber-reinforced thermoplastics, and hybrid manufacturing into a single, streamlined workflow.

The resulting monolithic tool demonstrates the viability of using large-format 3D printing for end-use deployment in highly regulated industries. By printing the tool as a single piece, the companies report that they have completely eliminated assembly joints, thereby removing assembly-driven failure modes and improving the long-term structural integrity of the mold.

The Shift to Hybrid Manufacturing in Aerospace

Combining Additive and Subtractive Processes

Rather than positioning LFAM merely as a shortcut for rapid prototyping, Caracol AM and Formes et Volumes implemented a comprehensive “hybrid workflow” to achieve strict aerospace-grade standards. According to the project details, the manufacturing process was broken down into three critical phases.

First, the Heron AM system, equipped with a High-Flow (HF) Extruder, printed the near-net-shape geometry directly from a digital model. This phase utilized precise robotic control and high deposition rates to form the core structure. Second, subtractive manufacturing via CNC milling was applied to the printed part. This step was essential to deliver the final dimensional accuracy, tight tolerances, and smooth surface quality required for aerospace molds. Finally, the tool underwent autoclave post-processing. Autoclave curing ensures the tool possesses the necessary thermal performance and stability to withstand the rigorous conditions of aerospace composite lamination.

Technical Specifications and Efficiency Gains

By the Numbers

The technical specifications released by Caracol AM highlight the scale and speed of the Heron AM platform. The composite lamination tool measures 2200 × 2200 × 600 mm and weighs 180 kg. Utilizing a Polycarbonate (PC) material reinforced with 20% Carbon Fiber and extruded through an 18 mm nozzle, the entire printing phase was completed in just 19 hours.

Moving from conventional tooling to this robotic LFAM approach delivered quantifiable efficiency gains across the production chain. The companies reported significant reductions in almost every major manufacturing metric.

According to the project data provided by Caracol AM, the hybrid LFAM workflow resulted in a 50% reduction in lead time, a 50% reduction in material waste, a 50% reduction in part weight, and a 30% reduction in overall production costs compared to traditional methods.

Furthermore, the digital design phase allowed engineers at Formes et Volumes to optimize internal geometries and mass distribution, bypassing the constraints typically imposed by traditional manufacturing limits.

Industry Implications and Supply Chain Resilience

AirPro News analysis

At AirPro News, we view this collaboration as a strong proof point that aerospace composite tooling is transitioning from a localized “test case” to an active industry standard. The successful deployment of the Heron AM platform for end-use aerospace tooling underscores a broader shift toward supply chain resilience. As hybrid manufacturing workflows mature, they enable more agile, on-demand production models. This allows aerospace manufacturers to produce critical tooling closer to the point of need, significantly reducing reliance on long, vulnerable legacy supply chains.

The financial momentum behind these technologies also cannot be ignored. In September 2025, Caracol AM raised a $40 million Series B funding round to accelerate its global expansion. This influx of capital suggests strong market confidence in LFAM solutions for heavy industries like aerospace, automotive, and marine manufacturing.

Additionally, the sustainability aspect of this project aligns with broader industrial goals. The reported 50% reduction in material waste is a critical step toward lowering the carbon footprint of heavy manufacturing. Formes et Volumes, based in Aytré, France, has historically been proactive in seeking environmentally friendly tooling solutions, including previous initiatives to recycle polystyrene from single-use boat molds. The integration of LFAM appears to be a natural progression of these sustainability efforts.

Frequently Asked Questions (FAQ)

What is LFAM?

LFAM stands for Large Format Additive Manufacturing. It is an industrial 3D printing process that uses robotic arms or large gantry systems to extrude polymers, metals, or composites to create large-scale parts and tooling.

What materials were used for the aerospace tool?

According to Caracol AM, the tool was printed using Polycarbonate (PC) reinforced with 20% Carbon Fiber, chosen for its thermal stability and strength.

Why is a monolithic structure important for aerospace tooling?

A monolithic (single-piece) structure eliminates the need for assembly joints. In aerospace tooling, joints can be points of weakness or failure. Removing them improves the long-term structural integrity and reliability of the mold.

Sources:
Caracol AM Official Press Release and Case Study