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Aerospace Manufacturing Solution
Advanced Manufacturing

Advanced manufacturing Technology

We provide advanced manufacturing services in technologies like 3d printing, CNC machining, vacuum casting, injection molding, laser cutting, etc.

Experienced Engineers


Team of expert engineers with more than 15 years of experience.

On Time Project Delivery

on time project delivery


With locations in all over Australia we can assure lightning fast delivery.

Australia Wide Expandation

Australia wide expandation


Zeal 3D is present in
Victoria, NSW, Western Australia,
Queensland and Tasmania.

ISO 9001 : 2015

ISO 9001-2015 certified


Committed to consistently provide products and services that meet customer and regulatory requirements and to demonstrate continuous improvement.

How Does Zeal 3D Help the Aerospace Industry by offering the services?

Customized Services: Zeal 3D consistently collaborates with current aerospace industry trends to address the rising demand for customized and reliable aerospace and avionics equipment.

Trusted by Various Industries: In the fields of aerospace and aviation, the creation of spare parts has seen the greatest impact from 3D engineering services. Zeal 3D supports businesses in producing premium customized solitary parts for the aerospace sector. Over the years, top Australian businesses have trusted us with their needs for manufacturing, prototyping, and product design.

Manufacture at Any Scale: Zeal 3D helps producers of the aerospace industry create aeronautical equipment and devices of any size, ranging from 1 to 10,000 pieces, whether it's for large or low volume production.

Increased Material Support: Zeal 3D uses more than 45 different materials to provide specialized 3D engineering services that are personalized to the demands and specifications of the client. Our staff will make the required effort to secure the supplies without requesting a minimum order quantity if you need manufacturing services utilizing materials that are not on the list (MOQ).

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High Quality Assurance: Zeal 3D takes great effort to assure quality assurance and consistently produce high-quality products with high precision tolerances in order to achieve the highest degree of client satisfaction.

Australia Wide Fastest Delivery: Zeal 3D provides the quickest delivery options across Australia, including Sydney, Brisbane, Perth, Tasmania, Melbourne, Canberra, Adelaide, and New Zealand.

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3d printing in Aerospace Industry
Aerospace Industry

High-End Services offered by Zeal 3D for Aerospace Industry

3D Printing

All facets of the aerospace sector are quickly experimenting with 3D printing, which is routinely utilised for quick prototyping and producing individual aeronautics models or spare parts. In comparison to traditional manufacturing methods, 3D printing has significantly cut the amount of time required for assembly, simplifying the design process and minimizing resource waste of aerospace products. Nevertheless, 3D printing makes it possible to create even complicated pieces effectively, which was previously almost impossible. Manufacturers can totally do away with tooling costs while still allowing their designers a lot of freedom. Zeal 3D Printing Services offers a variety of solutions in 3D printing materials for aerospace products along with their distinctive qualities.

Zeal 3D Specializations:

  • At Zeal 3D, we offer over 45+ industrial grade materials in plastic and metal that can be used to manufacture prototypes and end products for the aerospace industry.

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  • Additionally, we can also manufacture working prototypes with the integration of electronic systems, etc.
  • At Zeal 3D, we also provide post-processing operations, such as painting, sandblasting, polishing, plating, and screen printing.
  • We also have local trust from leading industries and organisations.
  • We offer the quickest delivery options throughout Australia.
  • For the aerospace industry, we provide 3D printing services using the materials like:
  • In addition, we offer 3D printing services for aerospace industry using cutting-edge technologies like:

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CNC Machining

Several significant aeronautical and astronautical components, including bushings, hinges, clamps, wall panels, assembling parts of fuel tanks and ventilation ducts, structural metal components, intricate gear cases and covers, and lightweight engine parts, are manufactured in the aerospace sector using CNC machining. Currently, CNC machining is a popular alternative for both prototyping and manufacturing of many aerospace components. CNC machining entails performing operations like drilling and cutting with computer control and automation.
To produce the desired end product, Zeal 3D uses a number of CNC machining techniques, including CNC milling, drilling, and turning. We also have 3, 5, and 7-axis CNC machines.

Zeal 3D Specialisations

  • At Zeal 3D, we offer a wide range of materials for manufacturing customised end-products, which you can choose based on your business needs and applications.
  • We provide highly precise production for end-products associated with the aerospace industry.
  • At Zeal 3D, we offer various post processing services, such as polishing, anodising, plating, plastic, itching, knurling etc.

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  • Additionally, we guarantee quality control in accordance with industry standards and requirements.
  • There is no minimum order quantity for CNC production, and we also offer CNC machining services for prototyping.
  • At Zeal 3D, we utilise a wide range of materials for CNC machining like:
    • Aluminium
    • Titanium
    • Bronze
    • Copper
    • Stainless steel
    • Plastic

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CNC milling
Vacuum Casting Australia

Vacuum Casting and Injection Moulding

High-end and dependable plastic components are made using the replicating technique known as vacuum casting. The use of a vacuum during the melting of metal material will likely be recognised as "vacuum casting" by people who closely work in manufacturing aerospace components. Many of the sophisticated alloys and superalloys utilised in this industry, like titanium and nickel-based alloys, are reactive with ambient oxygen or nitrogen. Additionally, this process offers a high-quality surface finish comparable to injection moulding and makes use of a variety of materials that are superior to industrial grade components. We at Zeal 3D can make a variety of vehicle parts for the aerospace sector using the vacuum casting method, including:

  • Valve Seals and Seats
  • Slide rails
  • Splines
  • Standoff insulators
  • Wear pads
  • Wire wrap
  • Cabin interiors
  • Valve components

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Some of the materials we use at Zeal 3D for Vacuum Casting includes:

  • ABS
  • Polypropylene
  • Polyethylene
  • Polyvinyl chloride
  • Nylon

The method of using a unique mould to make a plastic object is called injection moulding. Moulds are used to shape molten, malleable plastic into certain shapes. In the design of airplane and other aerospace systems, only the strongest plastics are employed. Nowadays, manufacturing spare components for the aircraft industry highly requires the use of injection moulding. Some of the aerospace products that can be made with the injection moulding process are:

  • Chassis Components
  • Cabin Spares
  • Subsequent Moulds
  • Bezels
  • Turbine housings
  • Turbine blades
  • Pin maps

At Zeal 3D, some of the most popular materials we use for plastic injection moulding are:

  • Acrylonitrile butadiene styrene (ABS)
  • Polyamide
  • Polypropylene
  • Polyvinyl chloride

Zeal 3D Specializations

  • At Zeal 3D, we provide high quality industrial grade materials equivalent in order to manufacture high-end components related to the aerospace industry.
  • Utilizing our cutting-edge technologies, we ensure a smooth surface finish and accuracy.
  • We use ABS, PP, and PE grade materials that are used for the production of end products.

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Laser Cutting and Fabrication

Aerospace vehicles need to be extremely precise and durable due to the harsh operating environments. Therefore, laser-cut components aren't just a novel concept; they are also the most effective technique to create the most precisely engineered parts with the highest level of efficiency. Laser cutting has increased efficiency across various industries, including aerospace. This is because less downtime is needed to produce the desired end goods. Additionally, if adjustments are necessary, they may be made quickly, allowing for the quickest possible return to optimum output. The aerospace parts that can be made with laser cutting are:

  • End effectors parts
  • Wing fasteners parts
  • Tooling parts
  • Fixture parts

At Zeal 3D, some of the materials used for the laser cutting process are:

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  • Stainless steel
  • Titanium
  • Plastic
  • Nickel alloys
  • Aluminium

The process of making a product or model out of various raw materials through cutting, mixing, and assembling parts is known as fabrication technology. Aerospace components will adhere to precise drawings or specifications that may entail cutting, rolling, and shaping, heating, or hammering metal goods to create parts or sub-assemblies in order to achieve an aesthetic finish and appearance.

Some of the materials used for fabrication process are:

  • Plastic
  • Sheet Metal
  • Steel
  • Brass
  • Aluminium

Zeal 3D Specializations

  • At Zeal 3D, we use high-end industrial grade materials in order to manufacture end-products related to the aerospace industry.
  • We use high-end laser cutting technologies to slice or cut a wide variety of materials such as wood, plastics, metals, leathers, papers, and others.
  • We offer customised service assistance based on your business needs and requirements.

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Laser Cutting in Melbourne
3D Designing for Aerospace Industry Manufacturing

3D Designing

3D designing in the aerospace industry is the process of designing or digitally drawing the appropriate end-product. Designers can specify and create rough layouts for the new product using the 3D design process, including the minimum die angle and filleting radii values. The CAD system automatically produces high-quality surfaces that comply with all the specifications given in the CAD design. The following are some advantages of choosing Zeal 3D to provide 3D design services to aerospace manufacturers:

  • Accelerated Project Completion Time
  • High-quality Manufacturing from Experienced Engineers
  • Staffing Flexibility
  • Reduce Costs
  • Better Control and Oversight

Zeal 3D offers high-end, cutting-edge 3D designing services that precisely represent your envisioned aerospace component model. We offer a wide range of 3D design services, including:

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  • Drafting
  • 2D to 3D conversions
  • 3D modelling
  • 3D Rendering
  • CAE Services like Analysis and Simulation (FEA)

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3D Scanning

In order to obtain three-dimensional information such as shape, colour, and texture about a component or object, the 3D scanning process uses structured light or lasers. With a state-of-the-art industrial 3D scanning system, Zeal 3D offers both on-site and off-site 3D scanning services. Typically, automotive businesses employ 3D scanning services to implement processes like:

  • Reverse engineering
  • Quality control inspection
  • New product development

Zeal 3D Specializations

  • At Zeal 3D, we offer both on-site and off-site industrial high-precision 3D scanning.
  • We also help clients with design and development assistance.
  • At Zeal 3D, we provide technical support across the whole product development process, right from the designing phase to mass manufacturing of end-products.
Augmented Reality for Aerospace

Augmented Reality

In the aerospace industry, augmented reality is accelerating manufacturing procedures for extremely complex applications that previously required lengthy ramp-up times. Since Augmented Reality applications are now more accurate, there is less danger, more safety, and a cheaper overall cost of production. The ability to prototype and build new equipment using augmented reality has the potential to dramatically speed up the prototyping and development process, enabling the production of new things to move more swiftly.

Augmented reality technology is widely used in various applications like:

  • Industrial training
  • Maintenance
  • Design Validations
  • High-end Stimulations

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Zeal 3D Specializations

At Zeal AR, we offer expert augmented reality services in developing Web AR and AR apps for a variety of sectors. Our augmented reality (AR) solutions for aircraft engineering may boost revenue, customer experience, and brand awareness for every size of product firm, from startups to small or existing businesses.
After discussing your needs and ideas with our AR services for various platforms, Zeal 3D gives you the perfect prototype of what you've been seeking.

Web AR: Using Web AR technology, clients can access augmented reality (AR) experiences straight from their web browsers without downloading any additional software.

Mobile AR: Zeal AR helps to execute the idea of augmented reality in a variety of formats, such as mobile applications, VR installations in stores, providing virtual tour experiences, and much more to draw in customers.

AR App Development: Zeal AR offers a wide range of business solutions, from WebAR to the creation of unique mobile applications tailored to your needs and use cases.

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Contract Manufacturing

  • In the aerospace sector, contract manufacturing entails a manufacturer entering into a formal agreement with a business to produce aerospace components or end-products.
  • Due to the lower production costs achieved through economies of scale, many businesses participate in aerospace contract manufacturing projects like aerospace contract machining.
  • Additionally, hiring an existing aerospace manufacturing plant is simpler than building one from scratch and hiring and training a team to produce a part.

Zeal 3D Specializations

  • Zeal 3D provides full-service contract manufacturing for the aerospace industry, which includes concept design, prototype development, product testing, and final production.
  • Our on-demand contract manufacturing services throughout Australia and the surrounding regions, including Melbourne, Brisbane, Sydney, Perth, Adelaide, Canberra, Tasmania, and New Zealand, can help you get your product to market quickly and inexpensively.
  • Zeal 3D uses top-of-the-line and intelligent production equipment, machines, and technology to make your idea a robust reality.
  • By utilizing our high-end contract manufacturing services, you end up with more flexibility and quality products.
3D Printing in Aerospace Industry
Aerospace 3D Printing

Type of Aerospace Parts We Manufacture at Zeal 3D

Jigs and fixtures: By using 3D engineering technology to produce the massive quantities of jigs and fixtures required, the aerospace industry can reduce production costs by 60 to 90 percent. Aerospace businesses can considerably benefit from 3D engineering services by using contract manufacturing technologies to produce specialized tooling equipment like jigs and fixtures on demand.

Interior Components: Aerospace applications, including the interiors and cabins of airplane, can greatly benefit from 3D-engineered plastic and metallic components. Commercial aircraft's cabin interiors must be maintained on a regular basis, which may require replacing parts like wall panels. Traditionally, injection moulding would be used to create new plastic components because of the limited volume, specialized needs, and high complexity required.

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Jet Engine Combustors: The traditional methods of producing jet engine combustors are notoriously challenging. High-quality components are created using a 3D engineering technique that utilizes cobalt-chrome alloy powder as the build material to shield the temperature sensor's extremely delicate electronics from soaring airflows and considerable engine icing. Other aircraft components, such as those utilized in ducting systems, are also being manufactured using 3D engineering techniques.

Spare Parts: Aerospace businesses are becoming more and more dependent on quick lead times due to their reliance on spare and replacement parts. The use of additive manufacturing and other 3D engineering services typically enables the speedy production of spare components when they are required. As a result, there is less need for large stockpiles, which lowers inventory costs and guarantees that parts are made locally.

Mounting Brackets: In order to mount complicated life-saving devices to the inside wall of a plane, structural, low-volume metal brackets are frequently manufactured using 3D printing technologies like DMSL/SLM and other 3D engineering services.

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Aerospace Industry

According to the market research report, the market for manufacturing aircraft parts was valued at USD 851.5 billion in 2021, and it is anticipated to increase at a CAGR of 4.0 percent from 2022 to 2030. Furthermore, Australia's aerospace industry is anticipated to see a CAGR of more than 4% over the course of the projection period (2022–2031). The Australian aviation engineering market is dominated by the Australian aircraft manufacturing and replacement services sector, which also plays a significant role in the Australian economy. The technical prowess of companies supporting the sector includes knowledge in aerospace engineering, space engineering, design, manufacturing aircraft parts, maintenance, research and development, and training. The Australian aircraft manufacturing and repair services sector holds a strong position on the global market with 600 enterprises participating in the global supply chain for aerospace manufacturing. Australia stands apart from its competitors and has a high degree of trust in its products across the worldwide market because of its number of critical capabilities and competencies in the aerospace sector.

3d printing for aerospace

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