Airframe Designs creates full-scale 3D-printed torpedo mock-up

Aerospace leader Airframe Designs has been working with a global prime defence contractor to create a full-scale 3D-printed mock-up of a torpedo-style weapon using polymer additive manufacturing.



Image courtesy Airframe Designs

The mock-up provides a physical and accurate visual representation of the artifact to help the customer evaluate the loading-unloading of the store to a new delivery platform.

In creating the mock-up design, ready for additive manufacturing, the team at Airframe Designs assessed the critical aspects of feasibility, accessibility and safety but also introduced stiffening features to ensure the mock-up could be handled with sufficient rigidity.

Jerrod Hartley, CEO of Airframe Designs, said: “Working with our partner, we created this mock-up in a very short lead time to ensure they had what they needed when they needed it.

“We thrive on providing bespoke solutions engineered and crafted specifically to help our customers reduce their project lead times and improve their cost-effectiveness.”

The 2.7 metres-long mock-up was designed by highly experienced engineers using computer-aided design with low-cost material and rapid prototype printers to create a lightweight, robust structure with the relevant torsional stiffness and overall robustness.

Large sections of the mock-up were printed using a Builder Pro large format 3D printer and toughened PLA material, with the final sections built on a Stratasys Fortus 450mc industrial FDM machine using ASA thermoplastic. Using different printers and material systems enabled the project to progress at pace whilst aligning technologies with the complexity of parts.

Meanwhile, Airframe Designs recently proved its commitment to environmental management and continual improvement by successfully achieving the prestigious ISO 14001 certification.

The audit required the organisation to assess environmental issues relevant to its operation including waste management, use of resources and efficiency.

Airframe Designs continues to grow its specialisms in producing highly complex components to some of the largest aviation, defence and space organisations worldwide.

Recent projects undertaken by the company include the integration of new systems into heavy lift drone platforms, conceptual design at a platform level for new uncrewed air-systems, test rig and tooling for electric vehicle propulsion systems and most recently the design and analysis of operator consoles for a special mission aircraft.

Related

Windracers ULTRA achieves first autonomous BVLOS flight in Indiana Drone Corridor
Image: ARI via Windracers
Windracers ULTRA achieves first autonomous BVLOS flight in Indiana Drone Corridor
A Purdue University-owned Windracers ULTRA has completed a landmark 50-mile BVLOS flight in Indiana, opening new possibilities for autonomous heavy-lift aviation operations.
Aerospace

4 Nov 2026

Delta vows to fight Heathrow terminal move that would separate it from Virgin Atlantic
Entrance Terminal 3 LHR
Delta vows to fight Heathrow terminal move that would separate it from Virgin Atlantic
The proposed relocation has sparked opposition from Delta and Virgin Atlantic with concerns that the decision could weaken transatlantic competition.
Aerospace

4 Nov 2026

RAF Chinooks deploy aboard Queen Elizabeth for maritime training drill
An RAF-operated Chinook HC6A (serial ZH896) lifts off from the flight deck of HMS Queen Elizabeth (R08) during Exercise Hathi Pol on 20 October 2026. Image: MOD Crown Copyright/Royal Air Force
RAF Chinooks deploy aboard Queen Elizabeth for maritime training drill
RAF Chinooks have embarked aboard HMS Queen Elizabeth, testing the UK’s heavy-lift tactical transport capabilities in a maritime environment during Exercise Hathi Pol.
Aerospace Defence

3 Nov 2026

Babcock brings seven firms into ARMOR Force as hybrid navy takes shape
Babcock's ARMOR Force concept for the hybrid Royal Navy
Babcock brings seven firms into ARMOR Force as hybrid navy takes shape
Seven companies have joined the framework as Babcock develops its vision of crewed warships commanding autonomous vessels carrying interchangeable mission systems.
Defence

4 Nov 2026

Yorkshire manufacturer David Brown Defence acquired by RENK
RENK Ann Kaiser
Yorkshire manufacturer David Brown Defence acquired by RENK
The acquisition of Huddersfield based David Brown Defence will expand the RENK Group's naval propulsion portfolio, strengthen its presence in the UK and the Five Eyes countries and support delivery of the Global Combat Ship (Type 26).
Defence Member News

4 Nov 2026

Royal International Air Tattoo moves to Boscombe Down in 2027
Red Arrows & VC10 - RIAT 2006
Royal International Air Tattoo moves to Boscombe Down in 2027
The Royal International Air Tattoo will move to MOD Boscombe Down in Wiltshire from 2027, ending more than four decades at RAF Fairford.
Defence

4 Nov 2026

Astroscale and OHB to collaborate on space security
Astroscale and OHB sign MoU
Astroscale and OHB to collaborate on space security
Following ratification of the Kensington Treaty in October, Astroscale and OHB have signed an MoU to enhance cooperation between the UK, Germany and Japan towards protecting critical infrastructure in space, whilst supporting the safe, sustainable and responsible use of the orbital environment.
UK Space Agency launches In-Orbit Manufacturing research competition
View_of_Harwell_campus_in_the_UK_article
UK Space Agency launches In-Orbit Manufacturing research competition
A new competition launched by the UK Space Agency (UKSA) seeks projects that will underpin the research, development and maturation of an In-Orbit Manufacturing process and associated payload.
Events Space

4 Nov 2026

QinetiQ to support Government’s tech talent drive
TechFirst
QinetiQ to support Government’s tech talent drive
By providing work experience opportunities and technology programmes, including cyber security, QinetiQ is supporting the UK Government TechFirst initiative, aimed at delivering practical skills and career support for young people.
Astroscale and OHB to collaborate on space security
Astroscale and OHB sign MoU
Astroscale and OHB to collaborate on space security
Following ratification of the Kensington Treaty in October, Astroscale and OHB have signed an MoU to enhance cooperation between the UK, Germany and Japan towards protecting critical infrastructure in space, whilst supporting the safe, sustainable and responsible use of the orbital environment.
UK SMEs offered 75% discount on Cyber Essentials certification under new scheme
CyberFirst Advanced at Lancaster University
UK SMEs offered 75% discount on Cyber Essentials certification under new scheme
The UK government has announced a new £2.4m fund which aims to make essential cyber security certification more affordable for British SMEs.
Security

4 Nov 2026

Supermarket cyberattacks expose wider UK security gaps as AI threat grows
Empty supermarket aisle with freezers showcases with different products
Supermarket cyberattacks expose wider UK security gaps as AI threat grows
Attacks on supermarket refrigeration networks have reached the UK supply chain, highlighting how vulnerabilities in operational technology could threaten businesses, public services and critical infrastructure.
Security

4 Nov 2026