The aerospace industry demands absolute precision, accountability, and reliability. Whether producing a flight-critical titanium bracket through metal 3D printing or manufacturing durable cockpit placards, aerospace printing services operate under some of the strictest quality standards in the world.

At the center of this system is AS9100, the globally recognized quality management standard developed specifically for aerospace manufacturers and suppliers.

Understanding AS9100 — and how aerospace printing services are performed under its requirements — helps clarify why these services are so highly regulated and who ultimately benefits from them.

What Is AS9100?

AS9100 is a Quality Management System (QMS) standard designed specifically for the aerospace industry. It is based on ISO 9001 but includes additional requirements focused on safety, risk mitigation, and regulatory compliance.

It is required — or strongly preferred — by most major aerospace OEMs and defense contractors.

AS9100 emphasizes:

• Risk-based thinking throughout production

• Strict documentation and record retention

• Full product and material traceability

• Configuration management and revision control

• Counterfeit part prevention

• Supplier oversight and approval systems

• Continuous improvement processes

In aerospace, failure is not just costly — it can be catastrophic. AS9100 exists to ensure that every part produced is consistent, traceable, and verifiably compliant.

What AS9100 Certification Requires

Becoming AS9100 certified is not simply about quality control at the end of production. It requires building a fully documented and audited system that governs the entire organization.

Certified companies must:

• Implement a documented Quality Management System

• Conduct internal audits

• Undergo third-party certification audits

• Maintain annual surveillance audits

• Retain documentation for extended periods

• Demonstrate process repeatability and control

In addition, aerospace suppliers often undergo customer audits before being placed on an Approved Vendor List (AVL).

AS9100 certification is ongoing — it requires continual monitoring, evaluation, and improvement.

What Are Aerospace Printing Services?

Aerospace printing services generally fall into two primary categories:

• Aerospace 3D Printing (Additive Manufacturing)

• Aerospace Industrial Printing (Marking, Labeling, and Documentation)

Both require strict adherence to compliance, traceability, and performance standards.

How Aerospace 3D Printing Is Performed

Additive manufacturing has become a powerful tool in aerospace because it enables lightweight structures, complex geometries, and part consolidation.

The process typically includes several tightly controlled steps.

1. Design & Engineering Validation

Parts are engineered specifically for additive manufacturing. Designs may include:

• Lattice structures for weight reduction

• Internal cooling channels

• Consolidated multi-part assemblies

• Topology-optimized geometries

Before printing begins, engineers perform:

• Structural analysis

• Thermal simulations

• Performance modeling

• Design validation reviews

2. Material Qualification

Only aerospace-grade materials are used, and every batch must include certification documentation.

Common materials include:

• Titanium alloys (Ti-6Al-4V)

• Inconel and other nickel superalloys

• Aerospace aluminum alloys

• Stainless steel

• High-performance thermoplastics like PEEK and ULTEM

Each lot must be traceable to its source.

3. Machine & Process Qualification

Because additive manufacturing is considered a “special process,” it must be validated to prove it consistently produces conforming parts.

Qualification includes:

• Machine calibration and maintenance logs

• Parameter validation

• Environmental controls (oxygen, humidity, temperature)

• Test builds for mechanical verification

• Statistical process validation

4. Printing & Production Controls

During production, providers maintain strict oversight of:

• Build environment conditions

• Powder handling procedures

• Operator training and certification

• Digital file control

• Machine data logging

All steps are recorded under AS9100 documentation protocols.

5. Post-Processing & Inspection

Printed parts typically undergo:

• Heat treatment

• Hot Isostatic Pressing (HIP)

• CNC finishing operations

• Surface treatment

• Non-destructive testing (NDT)

Final inspection may include:

• Dimensional verification

• Mechanical property testing

• Surface analysis

• First Article Inspection (FAI per AS9102)

Every result is documented and stored for traceability.

How Aerospace Industrial Printing Is Performed

Aerospace industrial printing focuses on producing durable, compliant materials used inside and outside aircraft.

These services may include:

• Cockpit placards

• Warning labels

• Aircraft data plates

• Control panel overlays

• Compliance labels

• Technical manuals and documentation

Because aircraft operate in extreme environments, printed materials must withstand:

• High and low temperatures

• UV exposure

• Chemicals and fuels

• Abrasion

• Vibration

The Production Process Includes:

• Strict artwork revision control

• Approved material sourcing

• Environmental durability testing

• Lot tracking and inspection

• Documentation retention

In some cases, materials must pass:

• FAA flammability testing

• MIL-STD durability requirements

• UL recognition standards

As with additive manufacturing, traceability and documentation are central to compliance.

Additional Compliance for Defense Applications

When aerospace printing services support military or defense contracts, additional requirements may apply.

These can include:

• ITAR registration

• NIST 800-171 cybersecurity controls

• CMMC compliance

• Secure data handling protocols

This ensures sensitive technical information is protected.

Who Benefits from Aerospace Printing Services?

Aerospace printing services create value across the entire supply chain.

Aerospace OEMs Benefit From:

• Weight reduction for improved fuel efficiency

• Faster prototyping cycles

• Reduced assembly complexity

• Improved design flexibility

Tier 1 & Tier 2 Suppliers Benefit From:

• Access to certified production partners

• Reduced capital investment in equipment

• Shorter development timelines

• On-demand production capabilities

Defense Contractors Benefit From:

• Secure manufacturing systems

• Full traceability and documentation

• Rapid replacement part production

• Compliance with strict regulatory frameworks

Airlines & MRO Providers Benefit From:

• Durable, regulation-compliant labeling

• Reduced aircraft downtime

• Faster access to replacement parts

Passengers Ultimately Benefit From:

• Increased aircraft safety

• Improved reliability

• Better fuel efficiency

• Reduced risk of part failure

Why AS9100 Is Central to Aerospace Printing

AS9100 ensures that aerospace printing services are not just about producing a part — they are about producing a controlled, traceable, and repeatable result.

Under AS9100:

• Every material lot is documented.

• Every process step is controlled.

• Every revision is tracked.

• Every risk is evaluated.

• Every part can be traced back to its origin.

This framework allows aerospace innovation — including advanced 3D printing — to move forward safely and reliably.

The Bottom Line

Aerospace printing services combine advanced manufacturing technology with rigorous quality control systems. Whether producing flight-critical metal components or high-durability aircraft labeling, providers must operate under disciplined processes governed by AS9100.

The result is a manufacturing environment where innovation and safety coexist — and where every printed component, marking, or part meets the demanding standards of modern aviation and space exploration.