How 3D Printed Aircraft Parts Are Transforming Aviation MRO

Spectrum Networks partners closely with ALOFT AeroArchitects, a leading completion and maintenance provider for VIP and special mission aircraft. While Spectrum designs and manufactures custom 3D printed aircraft parts using additive manufacturing, ALOFT installs and certifies those parts during major aircraft maintenance and interior upgrades. Together, they provide a complete aviation MRO solution that helps operators modernize aging fleets faster and more efficiently. 

One of Spectrum’s most common retrofit projects involves replacing outdated halogen lighting with efficient LED systems.

The challenge? Many aircraft panels still in service were designed 15–20 years ago, long before modern LED fixtures existed. Replacing the lighting often meant modifying every mounting hole in a ceiling panel, a costly and time-consuming task when dealing with more than 100 lights per aircraft. 

Instead, Spectrum designed a custom drop-in LED replacement, engineered with Markforged’s FX10 industrial 3D printer. The parts replicate the original form, fit, and function, so they can be installed directly into existing panels without altering the aircraft’s certified structure. 

“Before 3D printing, part availability for lights could take anywhere from three to six months,” says Colby Hall, Director of Technology, ALOFT AeroArchitects. “Now, we can deliver complete sets in just a few weeks.”

In aerospace manufacturing and aviation MRO, traceability and proof of conformance are critical. Every part that goes on an aircraft must meet its engineering drawing — and in many cases, must show proof that it does. 

Markforged’s FX10 addresses that need directly. Each layer of a printed part is inspected with a laser micrometer, generating a digital conformance report that verifies the part was printed to spec.

“For the FAA, that’s a big deal,” says Neil Gunnarson, President & COO of Spectrum Networks, “You can’t cut open every part to check it. The inspection data gives us objective proof that the part meets the requirements.” 

In 2024 alone, Spectrum Networks produced over 10,000 certified 3D printed aircraft parts that are flying today — a testament to how industrial additive manufacturing can meet aerospace’s most demanding standards.

By combining Onyx thermoplastic with continuous fiber reinforcement, Spectrum can create parts that are not only lightweight and durable but also structurally capable of handling real loads — perfect for interior mounts, housings, and enclosures. 

The surface quality of Markforged prints also helps Spectrum ship parts directly off the machine, no sanding or finishing required. That efficiency allows the company to scale production without sacrificing the premium fit and finish expected by its high-end clientele — including government and head-of-state aircraft operators.

The partnership between Spectrum Networks and ALOFT AeroArchitects illustrates a growing shift in aviation MRO. Instead of waiting months for obsolete parts, maintenance teams can leverage distributed additive manufacturing to print certified components closer to where they’re needed.

This approach reduces downtime, extends aircraft lifespan, and modernizes aging fleets — all while maintaining strict airworthiness standards. 

3D printed aircraft parts are becoming a key enabler for aviation MRO teams, providing flexibility, repeatability, and traceable quality in industries where precision and safety are non-negotiable.

As aircraft operators face increasing obsolescence challenges, additive manufacturing is transforming aviation MRO. Platforms like Markforged FX10 give aerospace suppliers the ability to react quickly, produce certified 3D printed aircraft parts with traceable quality data, and keep fleets operational longer. 

“It’s good to use equipment that’s designed for the future,” Gunnarson concludes. “That benefits everybody involved.”