A 3D printed lay-up tool capable of high-temperature and high-pressure autoclave cure cycles.

RapidResponse
Tooling
SSL cuts lead time forcustomized composite toolingby embracing 3D printing.
CHALLENGING THE NORM

Case Study

Over the last 30+ years, composite materials
have become increasingly relevant to a number ofindustrial sectors with applications that demand
the high strength of metals without their associatedweight. Although the composites industry has madesignificant breakthroughs in material science andproduction methods over the years, producing
complex composite parts can still be a lengthy andchallenging task that requires specific knowledge andexpertise. Traditional production methods for hightemperature composite tooling involve the expensive

Stratasys additive composite
tooling solutions have allowed
SSL to respond to design
releases and changes withunprecedented speed atsignificantly reduced cost,without compromising part
quality or performance.”
Jude Zils

Technology Manager
Composites Center of Excellence at SSL

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Rapid-Response
Toolingand time-consuming process of CNC machining.
Although machining is a repeatable and reliable
production method, the need for an operator andthe subtractive nature of the process result in highcosts, long lead times and significant material waste.
Stratasys FDM® technology can address all of thesepain points.
Evolving Innovation
SSL, based in Palo Alto, California, is a premierdesigner, manufacturer, and integrator of satellite
systems. They work at the forefront of satellite andcomposite technology. Maintaining industry leadershipmeans SSL is continually innovating and evolving
their approach to composite part and spacecraft
fabrication with improvements to materials, processes
and techniques.

up tool capable of the required 350 °F (180 °C),
high-pressure autoclave cure cycle in less than 48
hours (shipping time included), a 50% reductionin lead time. The time savings was critical in thiscase, highlighting one of the core advantages of 3D
printing.
According to Jude Zils, SSL Technology Manager,“Stratasys additive composite tooling solutions haveallowed SSL to respond to design releases andchanges with unprecedented speed at significantly
reduced cost, without compromising part quality
or performance. This game-changing technology isfacilitating a level of customization and rapid responsethat our customers can really appreciate.”

In partnership with Stratasys and using Fortus®
3D Printers, the latest technique that SSL has
implemented is additive manufacturing for rapidresponse, customized, high-temperature layup tooling. Although often overlooked, toolingapplications are proving to be among the mosteffective use cases for realizing significant andimmediate value with additive manufacturing, andSSL has implemented the technology for many suchapplications.
A Game Changer for Tooling
For years, SSL has used FDM technology for
prototyping and even some production parts. Morerecently, the SSL team benefited from using 3D
printing to produce customized high-temperature layup tooling in situations that are highly time-sensitive,
require rapid response, and necessitate complex,
custom geometries. In one such case, Stratasys
was able to provide SSL with a highly tailored lay-SSL uses 3D printed tooling in their satellite development.

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Case
StudyTitle Here2

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Rapid-Response
Tooling
Additive manufacturing allows SSL to eliminate thehigh costs and lengthy lead times typically associatedwith composite tool production. In situations thatare extremely time-sensitive, lead time is measured
in hours and days rather than the typical weeks ormonths for traditional composite tooling. Dependingon part complexity and size, a tool build can take justa few days, and quite frequently less than 24 hours.

This, compared with many days or even multiple
weeks for traditional machined tool assemblies,
affords SSL unprecedented levels of flexibility.
These time savings not only permit SSL to meet theincreasing demands of shorter customer lead times,
but also allow much greater design freedom andshorter product iteration cycles that result in superior
levels of part performance and functionality.

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Case Study

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