Tronosjet Manufacturing Achieves FAA Certification for Additively Manufactured Aerospace Part with Support from Renishaw

Tronosjet Manufacturing, a Canadian aircraft leasing and maintenance provider, has successfully gained FAA certification for one of the first additively manufactured (AM) metallic aerospace components under the Parts Manufacturer Approval (PMA) scheme. The part, a titanium engine thrust control pulley bracket, was produced using Renishaw’s advanced laser powder bed fusion (LPBF) AM systems, marking a significant milestone for the aerospace industry.

The bracket, traditionally made from cast magnesium, was chosen for its critical role in holding a pulley that redirects engine cables. By using additive manufacturing, Tronosjet was able to produce a more durable, corrosion-resistant component. The part was tested to exceed the FAA’s rigorous safety standards, including tensile, fatigue, and non-destructive testing (NDT). The titanium version demonstrated five times the strength of the original, with the printed part withstanding loads over 22,000lb compared to the original’s 4,000lb limit.

Renishaw’s AM250 system was instrumental in this achievement, offering high-quality production capabilities with the precision needed to meet FAA standards. Tronosjet’s decision to work with Renishaw was based on the company’s reputation for excellent engineering and process capability, along with its strong support network in North America. Over time, Tronosjet purchased three Renishaw AM systems, including the AM250, 500S Flex, and 500Q, all designed to produce complex metallic components with exceptional material properties.

“We are grateful for Renishaw’s engineering prowess and support — it delivered great products, which have been critical for us achieving certification,” said Jeff Campbell, Director of Maintenance and Manufacturing at Tronosjet Manufacturing. “This certification not only validates additive manufacturing for aerospace but also gives us a competitive edge in the market.”

With FAA certification now in place, Tronosjet can produce and supply the engine thrust control pulley bracket to customers, furthering its commitment to delivering innovative aerospace components. This marks a major step forward in demonstrating the viability of additive manufacturing in the aerospace sector.