Injection molding is one of...Read More
Holiday Closure Notice
Our office will be closed for the Christmas & New Year break from 16 December to 12 January.
Online orders via our Instant Quote Tool (Digifabster) remain available.
Holiday Closure Notice
Our office will be closed for the Christmas & New Year break from 16 December to 12 January.
Online orders via our Instant Quote Tool (Digifabster) remain available.
Accelerate development with lightweight, high-strength parts — made in Australia and delivered in as little as 24 hours.
3dm / STEP / STL / dwg accepted • No minimums • NDA-friendly
Every part is produced to exact specifications, with tight tolerances and consistent repeatability — ensuring mission-critical reliability for flight and field applications.
Fast local turnaround — get functional prototypes or replacement components in as little as 24 hours, without international shipping delays or export compliance headaches.
From topology-optimised designs to multi-material assemblies, our team manages the entire process — from file prep to inspection — so your engineers can stay focused on innovation.
Aerospace and defence engineers face constant trade-offs between weight, strength, cost, and lead time. With KAD3D, you don’t have to choose. We produce 3D printed aerospace components that meet the highest standards of dimensional accuracy, repeatability, and performance — whether you need a rapid prototype, a low-volume end-use part, or a flight-ready assembly for testing and validation.
Our local manufacturing and materials expertise allow you to iterate faster and eliminate overseas delays, supporting everything from R&D tooling and wind-tunnel models to custom enclosures, jigs, fixtures, and drone components. With certified materials, NDA protection, and 24-hour turnaround, we deliver parts that are mission-ready, inspection-ready, and field-ready — built right here in Australia.
Speed matters in aerospace and defence R&D. KAD3D enables engineers to move from CAD to physical prototype in less than 24 hours. Whether you’re validating a new UAV frame, testing aerodynamic flow, or evaluating fit before machining, our in-house FDM and SLA technologies provide exceptional dimensional accuracy and repeatability. By eliminating overseas lead times, you can test, iterate, and deploy faster—without compromising performance or compliance.
Additive manufacturing makes it possible to achieve what traditional machining can’t — stronger yet lighter components for flight and field applications. At KAD3D, we produce structural parts with advanced polymers and metals such as SLM Titanium (Ti-6Al-4V), carbon-fibre-reinforced nylon, and high-temperature engineering plastics, each chosen for its strength-to-weight efficiency and durability. Perfect for UAV fuselages, payload housings, satellite brackets, and defence enclosures, these parts deliver the reliability required for mission-critical operations while keeping mass low and performance high — all manufactured locally in Australia with precision and consistency.
Precision wind-tunnel testing demands smooth, accurate surfaces and consistent geometry. Using high-resolution SLA technology, KAD3D produces high-fidelity aerodynamic models that replicate true-to-scale airframe behaviour with exceptional surface finish and dimensional accuracy. Our team collaborates closely with engineers to refine surface textures, balance weight distribution, and deliver quick-iteration variants for reliable aerodynamic validation of lift, drag, and flow performance—all manufactured locally for fast turnaround and repeatable results.
For ground support, assembly, and inspection, custom jigs and fixtures are essential. KAD3D manufactures precision tools tailored to your workflow—from torque-limiting fixtures and locator jigs to handling frames and alignment aids. Additive manufacturing dramatically reduces the cost and turnaround compared to CNC machining, while maintaining the accuracy required for repeatable production or field servicing tasks.
When small-batch production is required, we bridge the gap between prototype and mass manufacturing. Our high-performance polymers and metal-composite filaments allow for durable, field-ready parts used in aircraft interiors, drones, and testing equipment. We maintain strict quality control and NDA-protected production for sensitive or classified projects, giving defence clients peace of mind alongside local, traceable supply.
KAD3D supports Australia’s defence innovation sector through the production of training aids, simulation models, and research prototypes. From scale models of vehicles and weapons systems to modular mock-ups for maintenance drills, we provide realistic, durable parts that enhance hands-on training and development programs. Every model is made locally with consistent quality assurance and confidentiality at the core.
At expos and defence industry trade shows, visual impact matters. KAD3D creates high-detail display models, scale aircraft replicas, weapon system mock-ups, and concept prototypes that capture attention and communicate innovation. Using SLA and SLS printing technologies, we deliver crisp details, smooth finishes, and paint-ready surfaces ideal for exhibitions, demonstrations, or investor showcases. Whether you need a scaled aircraft model, missile housing, or interactive assembly display, our team ensures your presentation is both technically accurate and visually stunning. Each piece is designed for easy transport, quick assembly, and durability under heavy handling—so your brand stands out wherever you exhibit.
Selecting the right production method is critical in aerospace and defence manufacturing, where tolerances, strength, and reliability define success. At KAD3D, we specialise in FDM, SLS/MJF, and SLM 3D printing — the three technologies most requested by aerospace and defence engineers for their ability to balance speed, strength, and complexity.
FDM (Fused Deposition Modelling) with PETG is the go-to choice for quick-turn jigs, fixtures, and fit checks, offering excellent dimensional stability and chemical resistance at low cost. SLS (Selective Laser Sintering) and MJF (Multi Jet Fusion) provide strong, functional nylon parts with superb mechanical performance and durability, ideal for housings, clips, brackets, and UAV components. For critical components and high-stress applications, SLM (Selective Laser Melting) in Titanium (Ti6Al4V), aluminum (AlSiMg10) and Stainless Steel (316L) delivers exceptional precision, lightweight strength, and thermal resistance.
While other technologies such as SLA, CJP, and vacuum casting are occasionally requested for visual or conceptual purposes, FDM, SLS/MJF, and SLM remain the core processes driving performance, reliability, and mission-readiness for our aerospace and defence clients.
| process | Best for | Materials | Max size | Key Advantages |
|---|---|---|---|---|
FDM (Fused Deposition Modelling) |
Cost-effective concept models, terrain, and massing studies |
PLA (cost-effective, fast, easy to finish) |
1000 × 1000 × 1000 mm (larger available on request) |
Affordable and fast, ideal for testing scale and form early in the design process. Excellent for large context bases or site models. |
SLA (Stereo-lithography) |
High-quality presentation, competition, and marketing models |
SLA KS408A Standard Resin (for fine detail); SLA KS408A Tough Resin (for extra strength) |
2700 × 900 × 800 mm |
Produces paint-ready, detailed parts perfect for façades, interiors, and client displays. Ideal when visual quality is the top priority. |
Laser Cutting |
Terrain, base plates, and large flat site components |
MDF, Acrylic, Cardboard (varies by project) |
1200 x 900 mm |
Perfect for terrain layers, contour mapping, and flat surfaces that support 3D printed elements. Ensures alignment, scale accuracy, and professional presentation. |
Every aerospace and defence project starts with choosing the right material for the mission. At KAD3D, we match each 3D printing process with materials engineered for strength, precision, and reliability under demanding conditions.
This material mix allows KAD3D to support every stage — from rapid R&D prototypes to flight-ready parts — all manufactured with full traceability and confidentiality.
At KAD3D, our post-processing options are designed to enhance performance, durability, and surface quality for mission-ready aerospace and defence components. Each finishing method is selected to suit the material and application — ensuring the highest reliability under demanding conditions.
By combining the right finishing method with each production technology, KAD3D ensures every part — from sealed nylon housings to polished titanium components — meets aerospace-grade standards for precision, reliability, and longevity, all manufactured locally in Australia.
| Finishing type | Available For | Description / Use Case |
|---|---|---|
|
Sanding & Priming |
SLA models |
Smooths layer lines and prepares parts for painting or display. |
|
Painting (Pantone / RAL) |
SLA models |
Colour-matched finishes for presentations, competitions, and client meetings. |
|
Clear Coating / UV Sealant |
SLA models |
Adds durability, UV protection, and gloss or matte finish for display models. |
|
Assembly & Modularity |
All models |
Models are pre-assembled where possible; modular design for easy transport and reassembly. |
|
Props & Landscaping |
All models |
Integration of trees, grass, cars, and figures for realistic presentation. |
Most aerospace and defence teams design their parts using advanced CAD tools such as SolidWorks, CATIA, Fusion 360, or Siemens NX, but these design files are often not immediately suitable for 3D printing or additive manufacturing. Geometries may require tolerance calibration, wall-thickness adjustments, or print-orientation optimisation to ensure the final part meets both functional and manufacturing constraints.
At KAD3D, our engineering team manages the entire digital-to-physical transition — from file repair and preparation to manufacturing and post-processing. Every model is carefully reviewed for dimensional accuracy, printability, and material compatibility, ensuring it performs as expected once produced. We handle support structure planning, geometry optimisation, scaling, and topology refinement, transforming complex digital designs into manufacturable, high-performance components.
Our team works with a wide range of industry-standard file formats including STEP, STP, IGES, STL, OBJ, and 3MF, and all data is handled within secure, NDA-protected workflows to maintain confidentiality for classified and proprietary projects.
By keeping every stage in-house, KAD3D ensures faster turnaround, consistent part quality, and full traceability from the initial file submission to final inspection. This seamless, closed-loop process helps aerospace and defence engineers move from digital prototype to flight- or field-ready part with confidence in both precision and reliability.
Engineers submit 3D files (STEP, IGES, STL, OBJ, 3MF, etc.) along with performance requirements, tolerances, and operating conditions.
Our design team reviews and repairs files, fixing geometry, scale, and wall thickness, and ensuring the part is optimised for the selected process (FDM, SLS, MJF, or SLM).
Components are produced using the most suitable technology and material — balancing precision, weight, and mechanical performance.
Depending on the technology and requirements, parts undergo polishing, electroplating, or Dichtol sealing to enhance strength, appearance, and environmental resistance.
Each part is inspected for dimensional accuracy, surface quality, and material integrity, then securely packaged and shipped from our Melbourne facility with full traceability documentation.
Our pricing for aerospace and defence components is based on the print volume, material, and process complexity. Every project is unique — from rapid prototypes to flight-ready metal parts — so each quote is individually assessed for accuracy, material performance, and post-processing requirements.
Costs are determined by part size, geometry, and selected technology (FDM, SLS, MJF, or SLM). Additional services such as polishing, electroplating, Dichtol sealing, or assembly are quoted separately to provide complete transparency.
This approach ensures procurement and engineering teams know exactly where their investment goes — from material and machine time to surface finishing and inspection. Whether you need a functional prototype, a validated fit-check tool, or a mission-critical titanium component, KAD3D provides itemised, no-surprise quotations for every project.
Lead times vary depending on the printing technology, material, and level of post-processing required. For simple FDM prototypes or jigs, production can often be completed within 24 hours.
SLS and MJF parts typically have a standard lead time of approximately 2 weeks, depending on size, complexity, and finishing requirements. For urgent projects, we also offer an express service delivering in as little as 3–5 business days.
SLM metal parts — such as titanium or stainless steel components — generally require 2–3 weeks, allowing for production, inspection, and any optional polishing, electroplating, or Dichtol sealing.
Every project is carefully planned to ensure the best balance of speed, precision, and reliability. With in-house production in Melbourne and secure nationwide delivery, KAD3D provides on-schedule, traceable manufacturing trusted by aerospace and defence teams across Australia.
Local pickup only available in melbourne, and next-day courier to metro areas are available. We also ship Australia-wide.
No MOQs—we’ll make one-offs or batches. Minimum order value is $55.
Click Instant Quote, upload your file, and choose material/finish. You’ll see pricing immediately; complex jobs can be manually reviewed on request.
STL, OBJ, STEP/STP, IGES/IGS, 3MF, DXF, DWG, and ZIP (up to 200 MB). If your file needs fixing, we can help.
All the majors: FDM, SLA, SLS, MJF; metals (SLM) on request. We’ll recommend the best option for strength, finish, and budget.
We prioritise tight tolerances and super-smooth finishes (especially with SLA). Tell us your critical dimensions and we’ll confirm achievable specs before printing.
Absolutely. Share how the part will be used (load, heat, UV, chemicals) and we’ll guide you—starting with cost-effective options first.
Yes. We’re NDA-friendly and handle all files securely. Only the engineering team sees your data.
Yes—B2C and B2B. We support prototypes, end-use parts, and short-run production to anyone in australia
what our clients says about kad3D
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