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Download the Resource Guide

aircraft maintenance 3d printed engine duct

Discover how aerospace and automotive innovators are transforming Environmental Control System (ECS) ducting with Fused Deposition Modeling (FDM®) 3D printing. This design guide—developed by Stratasys in collaboration with Raytheon and the Air Force Research Labs—equips engineers and manufacturers with the tools to design, build, and validate high-performance ECS ducts using ULTEM™ 9085 resin.

stratasys fdm ultem9085 3d printed duct

What You’ll Learn

  • Design Best Practices - From wall thickness and overhang angles to bifurcations and integrated mounting features—optimize your duct geometry for additive manufacturing.
  • Material Insights - Understand the thermal, pressure, and lifecycle performance of ULTEM™ 9085 resin, a flame-retardant, aerospace-grade thermoplastic.
  • Advanced Processing Techniques - Master Insight™ software settings including build orientation, seam control, remnant fill, and support generation to reduce porosity and improve sealing.
  • Post-Processing & Sealing Methods - Compare brushing, spraying, vacuum impregnation, and painting techniques to achieve airtight performance—even under high pressure.
  • Real-World Testing Data - Explore leak, burst, and mechanical testing results that validate FDM ducting for production use in demanding environments.

Why Download This Guide?

  • Reduce cost and lead time for low-volume or complex duct geometries
  • Eliminate assembly steps with integrated features
  • Improve performance with data-backed design and sealing strategies
  • Accelerate prototyping and production with confidence

Fill out the form to access your free copy of the ECS Ducting Design Guide and start building better, lighter, and more efficient ducts with FDM technology.

3d printed duct airflow testing setup