Connect with us

MRO & Manufacturing

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

Caracol AM and Formes et Volumes use robotic LFAM and hybrid manufacturing to produce a large aerospace composite tool, reducing lead time and costs.

Published

on

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

Photo Credit: Caracol AM

Continue Reading
Click to comment

Leave a Reply

MRO & Manufacturing

GE Aerospace CNC Apprenticeship Graduates 80 in First Year

GE Aerospace marks one year of its Wilmington, NC CNC machinist apprenticeship, graduating 80+ participants trained to produce jet engine components.

Published

on

GE Aerospace announced on August 25, 2026, that more than 80 participants have graduated from its Computer Numerical Control (CNC) machinist apprenticeship program in Wilmington, North Carolina, during the initiative’s first year of operation. The milestone highlights the manufacturer’s ongoing efforts to alleviate aerospace supply chain constraints by accelerating the training of skilled labor for critical jet engine component production.

In a press release issued to mark the program’s anniversary, GE Aerospace detailed that the eight-week training pipeline was developed in partnership with Cape Fear Community College (CFCC). The initiative supports the production of precision core engine parts, including blisks, spools, and high-pressure turbine disks, which are currently in high demand across both commercial and military aviation sectors.

Workforce development and training structure

The apprenticeship model condenses the initial skills acquisition phase into an eight-week window. Participants undergo five weeks of intensive instruction at CFCC facilities before moving to the GE Aerospace plant floor for applied training. The curriculum is designed to transition individuals with no prior aviation manufacturing experience into capable CNC machinists. The program is also supported by funding from North Carolina’s NCEdge initiative.

Mark Moon, the GE Aerospace site leader in Wilmington, stated that the program is essential for growing the local workforce required to deliver critical engine parts to customers. The initiative targets candidates from diverse professional backgrounds who are looking to enter the aerospace manufacturing sector.

“I joined the apprenticeship program to pursue a new career path and create a better future for myself and my family. It’s a great way to step into this field where you can thrive and make a career out of it,” said Joseph Knox, a recent graduate of the program.

Broader manufacturing investments

The Wilmington apprenticeship program operates within the context of a $1 billion U.S. manufacturing investment planned by GE Aerospace for 2026. Of that total, the company allocated $160 million to its North Carolina facilities, with $60 million specifically directed to the Wilmington site to expand capacity and upgrade equipment.

The educational partnership builds on prior philanthropic investments in the region. The GE Aerospace Foundation awarded a $100,000 grant to CFCC in 2024 to support machining bootcamps and scholarships. Additionally, the foundation donated $500,000 in 2025 to the Manufacturing Institute’s Heroes MAKE America initiative. CFCC President Jim Morton noted that the collaboration illustrates the function of community colleges in building the talent pipelines necessary to support regional economic and industrial expansion.

AirPro News analysis

We view the rapid scaling of the Wilmington apprenticeship program as a direct response to the persistent skilled labor shortages bottlenecking global engine production and maintenance, repair, and overhaul (MRO) networks. By vertically integrating the training process and partnering directly with local educational institutions, original equipment manufacturers (OEMs) like GE Aerospace can bypass traditional, slower labor acquisition methods. The specific focus on CNC machining for high-pressure turbine disks and blisks targets the exact components that have historically paced engine delivery schedules and constrained aftermarket support.

Sources: GE Aerospace

Photo Credit: GE Aerospace

Continue Reading

MRO & Manufacturing

AAE Opens 1900sqm MRO Facility at Albury Airport Australia

Australian Aerospace Engineering opens a new MRO facility in Albury, NSW, supporting UH-60M Black Hawk sustainment for the Australian Army.

Published

on

Australian Aerospace Engineering (AAE) officially opened a new 1,900-square-meter Maintenance, Repair, and Overhaul (MRO) facility adjacent to Albury Airport (ABX) in New South Wales on August 25, 2026. The purpose-built site consolidates the company’s aerospace maintenance and manufacturing capabilities to support domestic aviation and defense operations.

In a press release issued on August 25, AAE detailed that the new infrastructure expands its capacity to perform complex aerospace work domestically. The opening coincides with an expanded Partnerships announcement from Lockheed Martin Australia, integrating the Albury facility into the sustainment network for the Australian Army’s UH-60M Black Hawk Helicopters fleet.

Facility capabilities and defense integration

The new site brings together multiple specialized services under one roof. These include aircraft maintenance, component overhaul, non-destructive testing (NDT), machining, manufacturing, spare-parts storage, and specialist surface treatment. The facility features a semi-downdraft heated spray booth and an adjoining helipad designed specifically to support maintenance operations for medium to large helicopter platforms.

The infrastructure investment directly supports AAE’s growing role in the Australian defense supply chain. On the same day as the facility opening, Lockheed Martin Australia confirmed the site will support the sustainment of the Australian Army’s UH-60M Black Hawk fleet. AAE also lists Sikorsky Australia, Pilatus Australia, and BAE Systems among its defense and aerospace partners.

Regional economic impact and company growth

The Albury facility marks a significant expansion for AAE, which has operated for more than 20 years. The company has grown its workforce from an initial three-person family business to a current team of 14 employees.

Justin Clancy MP, Member for Albury, officiated the opening ceremony. He noted that the facility provides a foundation for ongoing growth, including the addition of new engineering and technical roles in the coming years.

“The opening of AAE’s new facility is a fantastic outcome for Albury, creating opportunities for highly skilled local jobs and demonstrating what regional Australian businesses can achieve in advanced aerospace and Defence Industries,” Clancy said.

AAE Chief Executive Officer Adam Johnston stated that the new site gives the company the space and resources required to take on more complex work. Prior to the formal opening, the Governor of New South Wales, Margaret Beazley, conducted an official tour of the newly constructed facility on February 18, 2026.

AirPro News analysis

We view the expansion of regional MRO capabilities in Australia as a critical step in building sovereign defense industrial capacity. By locating specialized services like NDT and component overhaul outside major metropolitan hubs, companies like AAE reduce supply chain bottlenecks for critical platforms like the UH-60M Black Hawk. The integration of a dedicated helipad and specialized spray booth indicates a clear strategic focus on rotary-wing sustainment, positioning the Albury site as a specialized node in the broader Lockheed Martin and Sikorsky Australia support network.

Sources: Australian Aerospace Engineering

Photo Credit: Australian Aerospace Engineering

Continue Reading

MRO & Manufacturing

Lion Group Opens Batam Aero Engine MRO Facility in Indonesia

Lion Group launched Batam Aero Engine on Aug 19, 2026, offering engine and APU MRO services to serve Southeast Asian operators.

Published

on

Lion Group has officially commenced operations at its new Batam Aero Engine maintenance, repair, and overhaul (MRO) facility in Indonesia, aiming to capture a larger share of the Asian engine maintenance market and reduce domestic reliance on foreign service providers.

The facility, which opened on August 19, 2026, provides both on-wing and off-wing maintenance for jet engines, turboprop engines, and Auxiliary Power Units (APUs). The Launch was detailed in a press release issued by Lion Group on August 21, 2026, highlighting the company’s push to localize critical aviation supply chains.

Technical capabilities and infrastructure

Batam Aero Engine enters the market with specialized diagnostic and repair capabilities designed to service a variety of powerplants. According to the Lion Group press release, the facility is equipped to perform complex procedures including Low Pressure Turbine (LPT) module replacements.

The maintenance center also features advanced borescope inspection equipment. Certified personnel will utilize IPLEX NX, IPLEX GX/GT, and Mentor Flex systems to conduct internal engine diagnostics. These capabilities allow technicians to assess engine health and identify potential defects without requiring full engine teardowns, thereby reducing maintenance turnaround times for operators.

Strategic expansion in the Asian MRO market

The inauguration event in Batam drew key figures from both the company and Indonesian regulatory bodies, including Lion Group Founder Rusdi Kirana and Batam Mayor Dr. Amsakar Achmad. The strategic placement of the facility in Batam leverages existing industrial infrastructure and proximity to regional trade routes to attract maintenance contracts from across Southeast Asia-Pacific.

Lion Group President Director Captain Daniel Putut Kuncoro Adi emphasized the dual focus of the new enterprise.

“We hope this facility can serve domestic needs as well as friendly countries and further strengthen Indonesia’s aviation industry,” Adi stated, according to reporting by Aviation Business News.

Indonesian regulators also view the facility as a step toward greater self-sufficiency in the aviation sector. Sokhib Al Rokhman, Director of Airworthiness and Aircraft Operations at Indonesia’s Directorate General of Civil Aviation (DGCA), highlighted the broader national strategy during the launch.

“We want to strengthen aviation independence by making Batam Aero Engine an MRO hub that is efficient, responsive, and competitive in the Asian market,” Rokhman said, as reported by ePlaneAI.

AirPro News analysis

The establishment of Batam Aero Engine represents a calculated vertical integration Strategy by Lion Group. By bringing engine and APU maintenance in-house, the operator can better control maintenance costs and mitigate Supply-Chain bottlenecks that have constrained the global MRO sector in recent years. Furthermore, positioning the facility in Batam allows Indonesia to compete directly with established MRO hubs in neighboring Singapore and Malaysia. If the facility can secure third-party contracts as intended, it will mark a significant maturation of Indonesia’s domestic aviation technical capabilities and workforce.

Sources: Lion Air Public Relations

Photo Credit: Batam Aero Engine

Continue Reading
Every coffee directly supports the work behind the headlines.

Support AirPro News!

Advertisement

Follow Us

newsletter

Latest

Categories

Tags

Every coffee directly supports the work behind the headlines.

Support AirPro News!

Popular News