Renishaw-Powered Additive Manufacturing Breakthrough Earns Tronosjet FAA Certification for Critical Aircraft Part!

In a landmark achievement for aerospace additive manufacturing, Tronosjet Manufacturing has successfully received FAA Parts Manufacturer Approval (PMA) for a safety-critical engine thrust control pulley bracket, produced using Renishaw’s Laser Powder Bed Fusion (LPBF) additive manufacturing systems. This certification marks a rare milestone in the aviation industry, where few 3D printed metal parts have cleared the stringent safety and reliability thresholds required by the Federal Aviation Administration.

Tronosjet, a Canadian-based company with deep expertise in aircraft leasing, maintenance, and modification, has steadily expanded into the advanced manufacturing space since 2016. Through its dedicated AM division, the company provides end-to-end capabilities—design, heat treatment, post-processing, metallurgical testing, and regulatory compliance—for producing aerospace components under Transport Canada 561 and AS9100 quality certifications.

The breakthrough came when Tronosjet selected a BAe 146 aircraft component—the engine thrust control pulley bracket, originally cast in corrosion-prone magnesium—to be redesigned and printed using aerospace-grade Ti-6Al-4V titanium alloy. This bracket, essential for engine control cable routing, was deemed a Class 1 critical part by the FAA, meaning its failure could endanger aircraft safety. The Tronosjet team demonstrated that the 3D printed titanium bracket could withstand loads of over 22,000 lb, more than five times the breaking strength of the original magnesium casting, which failed at just 4,000 lb.

To achieve such precision and repeatability, Tronosjet relied on three Renishaw AM systems, choosing a single-laser, no powder recirculation setup to maintain tight control over process variables. The robust machines enabled the consistent fabrication of complex aerospace components with the confidence needed for regulatory approval. Extensive non-destructive testing (NDT), static, functional, and destructive analysis validated the part’s strength, consistency, and overall airworthiness.

Following rigorous testing and demonstration of repeatable production quality, the FAA granted PMA certification for the 3D printed bracket. This milestone not only allows Tronosjet to manufacture and supply the part commercially, but also positions the company as a pioneer in certified metallic additive manufacturing for the aerospace sector.

Jeff Campbell, Director of Maintenance and Manufacturing at Tronosjet, emphasized the impact of this achievement: “We knew additive could deliver the strength and reliability needed. Getting this part FAA-certified was key to proving AM’s potential in aerospace. We’re grateful for Renishaw’s engineering support—it’s been instrumental in reaching this goal.”

This certification represents a significant validation of additive manufacturing’s role in next-generation aerospace production, providing Tronosjet with a competitive edge and paving the way for broader adoption of AM in safety-critical applications.