Airframe Designs Accelerates Growth with 3-D Scanning and Additive Manufacturing

Blackpool-based aerospace engineering specialist Airframe Designs, founded in 2009, has transformed its business by embracing cutting-edge digital manufacturing technologies. Initially providing structural analysis services to the aerospace sector, the company diversified during the Covid-19 pandemic by launching a new manufacturing division focused on additive manufacturing (AM) and expanding internationally.

A key driver of this transformation has been Airframe Designs’ investment in advanced 3-D scanning technology, supported by a £20,000 grant from the Government-backed Made Smarter adoption programme—a national initiative aimed at boosting productivity and growth in UK manufacturing through digitalisation.

This initial grant enabled the company to invest £40,000 in a high-tech 3-D laser scanner, which allows precise scanning and reverse engineering of aircraft components, efficient damage assessment, and streamlined design and manufacturing workflows. This early step laid the groundwork for a dedicated 3-D division, now equipped with an advanced scanner featuring photogrammetry capabilities, enabling work on large-scale parts including entire airframe structures.

Jerrod Hartley, CEO of Airframe Designs, explained:

“The technology and innovation that the scanner brings is game-changing. The support from Made Smarter has been fantastic and really accelerated our plans. Without it, we wouldn’t be in the position we are now.”

Rapid Expansion and Skilled Workforce Development

Since integrating scanning and digital manufacturing, Airframe Designs has tripled its workforce to 33 employees since 2022 and plans to add 20 more in the next two years. The manufacturing division now produces hundreds of parts annually, aiming to exceed 1,500 in the near future. Alongside recruitment, six apprentices and several existing employees have been upskilled in scanning and additive manufacturing processes, strengthening the company’s technical capabilities.

Recently, Airframe Designs completed a major six-month project for a large Middle Eastern airline, reverse engineering and manufacturing obsolete or hard-to-source cabin interior parts no longer supported by OEMs. This project highlights the company’s growing global footprint and ability to solve complex supply chain challenges.

Donna Edwards, Made Smarter’s adoption programme director, praised the company:

“Airframe Designs is a powerful example of how digital technology, backed by targeted support, can drive innovation, resilience and growth in UK manufacturing. By embracing 3-D scanning and additive manufacturing, the business has not only transformed its operations but also created high-value jobs and opened up new global markets.”

Airframe Designs’ success story showcases the potential of digitalisation to revolutionise aerospace manufacturing and secure competitive advantage in a rapidly evolving global industry.