Formes et Volumes, a France-based machine shop specializing in prototypes, molds and professional models, recently partnered with LFAM specialist Caracol to produce a large-scale composite lamination tool for aerospace manufacturing. The 3D printed tool, which had overall dimensions of 2200 × 2200 × 600 mm, enabled Formes et Volumes to substantially accelerate lead times, reduce costs, and minimize waste compared to conventional tool production.

In the aerospace industry, lamination tools are critical in the production of lightweight composite structures. For large composite parts, however, tooling has long presented challenges. For one, creating large composite lamination tools has typically required the production of multiple sections which must be assembled, introducing misalignment risks. For another, shaping has largely relied on CNC machining, which generates substantial waste and eats up time.

As Caracol puts it: “Multi-component assemblies increase misalignment risk. Long machining cycles stretch lead times. Logistics and tooling complexity drive up costs. The result is a production model that struggles to keep pace with the demands of modern aerospace programs.”

Large-format additive manufacturing solutions such as Caracol’s Heron AM platform have been changing this reality, enabling the production of monolithic, near-net-shape tools that completely eliminate the need for assembly, minimize machining requirements, and open up greater design freedom.

This capability was demonstrated by Formes et Volumes, which worked with Caracol to design and 3D print a composite lamination tool for the aerospace industry. The tool, which is now being used in an “active industrial environment”, was made by the Heron AM robotic 3D printer equipped with a high-flow (HF) extruder using polycarbonate (PC) with 20% carbon fiber reinforcement.

The production process for the large-scale conical tool involved three basic steps. First, the near-net-shape tooling structure was printed. The printing itself took 19 hours to complete. Next, the tool was CNC machined to specification, ensuring the correct tolerances and optimal surface finish. Finally, the tool was post-processed in an autoclave, which imparted adequate thermal performance for aerospace composite lamination. You’ll notice that at no point was assembly required to realize the 180 kg part, thanks to the monolithic nature of the print.

By opting to use LFAM instead of conventional production processes, Formes et Volumes saw several benefits, including a 50% reduction in tooling lead time, a 30% reduction in production costs, and a 50% reduction in material waste. In terms of performance, the 3D printed tool was 50% lighter than its conventional counterpart thanks to an optimized internal structure and was not plagued by the risk of assembly-driven failure due to its monolithic nature.

“This project with Formes et Volumes is proof point for a broader shift in aerospace production,” Caracol stated. “As robotic LFAM matures alongside hybrid manufacturing workflows, platforms like Heron AM are enabling more agile, on-demand production models, reducing dependency on long supply chains and legacy tooling infrastructure.”

Based in Milan, Caracol has applied its LFAM technology for a range of large-scale applications. Among its recent use cases are a six-meter monolithic catamaran 3D printed in cooperation with V2, a directly 3D printed full-size sports car roof, and a recreational vehicle (RV) cab made using recycled materials.