3Deus Dynamics’ Dynamic Moulding: a Gravity‑Free, EN9100‑Certified Additive Manufacturing Breakthrough for Aerospace Series Production

A New Generation of Additive Manufacturing for Aerospace

Additive manufacturing has been widely adopted in aerospace for prototyping and design validation, yet its transition to certified series production remains limited. Most 3D printing technologies struggle with repeatability, industrial throughput and compliance with aerospace quality standards.

3Deus Dynamics’  “Dynamic Moulding” (DYMO) changes this equation.

Developed by 3Deus Dynamics, Dynamic Moulding is a patented gravity‑free, mould‑less additive manufacturing process specifically suited for industrial deployment. Rather than adapting prototyping technologies to production constraints, DYMO has been engineered from the outset to support serial manufacturing under EN9100 certification.

• Gravity‑Free Manufacturing Enables Unprecedented Functional Integration

This YouTube video depicts the process better than words: https://www.youtube.com/watch?v=wVzh9kUeqyQ&themeRefresh=1

Unlike conventional additive processes, Dynamic Moulding operates independently of gravity and traditional tooling. This enables the creation of highly complex internal architectures that would be impossible to form using mould‑based or layer‑by‑layer printing methods.

The technology llows aerospace manufacturers to consolidate multiple functions into a single monolithic part manufactured in augmented silicones, delivering:

• Extreme flame resistance compliant with aerospace safety requirements : see kerosene flame burns test via the following link:https://www.linkedin.com/posts/jpp31_fascinante-cette-teinte-violette-que-finit-activity-7432018418939174912-Ou1G?utm_source=share&utm_medium=member_desktop&rcm=ACoAABYrRAgBD23_2t7OxfAOsrg8qskgqKqKznU
• Highly effective EMI shielding for avionics and electronic protection
• Electrical conductivity integrated directly into the part
• Complex internal geometries optimised for performance and weight. See their funny video « UPO , the UnPrintable Object » on LinkedIn: https://www.linkedin.com/posts/jpp31_augmentedsilicone-additivemanufacturing-gravityfree-activity-7447811557096517632-i5ey?utm_source=share&utm_medium=member_desktop&rcm=ACoAABYrRAgBD23_2t7OxfAOsrg8qskgqKqKznU
• Monolithic angles and junctions: no fit, no cut, no bond means ensured functionality and substantial cost savings for your series production.

This functional integration reduces part count, assembly operations and potential failure points—key drivers for weight reduction and system reliability in aerospace platforms.

• EN9100 Certification: From Additive Promise to Production Reality

A major differentiator of 3Deus Dynamics is EN9100‑certified quality system. While additive manufacturing is often associated with low‑volume or experimental use, DYMO demonstrates that automated additive processes can meet aerospace standards for quality management, traceability and process control.

Fully automated production lines ensure:

• repeatable cycle times,
• controlled process parameters,
• documented quality assurance,
• and stable industrial output suitable for long‑term aerospace programmes.

This positions Dynamic Moulding among the very few additive manufacturing technologies capable of supporting serial aerospace and defence applications, rather than remaining confined to prototypes or demonstrators.

• Reducing Lead Times, Tooling and Environmental Impact

By eliminating traditional moulds and tooling, Dynamic Moulding significantly reduces non‑recurring costs and development lead times. Design iterations can be implemented rapidly without investment in new tooling, supporting agile development and accelerated qualification cycles.

Additionally, the absence of tooling and optimized material usage contribute to a lower environmental footprint, fully REACH, RoHS compliant, Pfas-free, using no organic solvent and only inert powders and pure silicone, aligning with emerging as well as future sustainability objectives within the aerospace industry.

• A Certified Path Forward for Additive Aerospace and Defence Manufacturing

Dynamic Moulding illustrates a critical shift in additive manufacturing: from experimental freedom to certified industrial capability. By combining gravity‑free manufacturing, augmented silicone materials and EN9100‑compliant production, it delivers a credible route to series production without compromising performance, repeatability or reliability.

Beyond cost reduction and time‑to‑market advantages, the technology also contributes to a reduced environmental footprint, through the elimination of tooling and optimised material usage—an increasingly important consideration for aerospace programmes.

Equally significant is its contribution to European industrial sovereignty. By providing a certified, scalable manufacturing technology 100% developed and industrialised in Europe, with no dependance on global supply chains, Dynamic Moulding supports strategic autonomy across critical aerospace and defence supply chains, reducing dependence on non‑European production capabilities.

With its compatibility with aerospace and defence certification frameworks, Dynamic Moulding is explicitly positioned to address defence applications, where functional integration, reliability, traceability and long‑term production stability are essential.

Dynamic Moulding therefore represents more than an advanced manufacturing innovation: it is a strategic production technology, aligned with Europe’s aerospace, defence and sovereignty objectives.

• For the UK aerospace and defence industrial base, the implications are tangible.
  
  

Maintaining competitiveness across long‑term programmes increasingly depends on the ability to combine certified production, supply‑chain resilience and advanced manufacturing capabilities. Technologies that can deliver innovation while meeting the stringent requirements of series production are becoming essential at prime and Tier‑1 level.

Dynamic Moulding offers a certified, scalable and production‑ready approach aligned with these priorities. UK aerospace and defence stakeholders—including primes, Tier‑1 suppliers and programme authorities—are encouraged to assess how this gravity‑free, EN9100‑certified technology can support current and future platform needs.

For further information, contact 3Deus Dynamics:

Jean‑Philippe Pysarevitch

Business Development Manager Aerospace & Defence

jp.pysarevitch@3deusdynamics.com

+33 7 44 88 09 43