Large-Format 3D Printed Tooling Targets Composite Layup, Forming and Assembly

Source | AES

Additive Engineering Solutions (AES, Akron, Ohio, U.S.) is a contract manufacturer specializing in large-format additive manufacturing (LFAM) services for composite tooling and large-scale prototyping. Founded in 2016, AES operates five LFAM printers and seven large CNC machines, offering capabilities that include a 32' multi-component CNC mill fixture among its current tooling portfolio, which the company is highlighting at CAMX in addition to tooling examples. In 2026, AES expanded into a larger facility and added printer and CNC mill capacity to meet growing production demand.

AES produces LFAM tools machined to global profile tolerances of ±0.010". The company works with a range of fiber-reinforced polymer materials — including ABS, PETG, PC, PLA and PEI, each reinforced with carbon or glass fiber — selected based on application requirements. Tooling offerings encompass layup tools rated to 400°F, process tooling, forming and assembly tools, and precast concrete tooling, serving aerospace, defense, general aviation, marine and space industries. According to AES, LFAM technology can reduce project schedules by up to 50% and costs by 10-40% compared to conventional approaches.

Beyond tooling, AES produces large-scale mockups, full-scale engineering mockups, marketing displays and assembly verification articles. The company holds AS9100 Quality Management System certification and maintains compliance with ITAR, CUI and NIST Cybersecurity standards for work in regulated sectors.