From prototype to cloud: Boom Supersonic and the Power of 3D Printing

Boom Supersonic is reshaping the future of air travel layer by layer. Using 3D printing, it is accelerating supersonic aircraft development, reducing costs and enabling designers to test and produce complex parts and tooling faster than ever before. Read how modern technology is turning dreams of supersonic travel into reality.

Colorado-based Boom Supersonic was founded with a bold vision: to return supersonic flight to commercial transportation in a way that is sustainable and economically viable. Their plane, the Overture, is set to be the world's fastest transport aircraft, cutting long-haul flight times by up to half, with a zero carbon footprint.

To prove it, the company is developing a one-in-three scale XB-1 demonstration aircraft on which it is testing key technologies for safe flight.

However, the path to this goal is not easy. Boom Supersonic has to deal with high costs, complex prototyping and the need to react quickly to design changes. This is where 3D printing comes in.

Speed and flexibility through additive technologies

It was clear from the start that 3D printing would be key for Boom Supersonic. With Stratasys 3D printers, experts could quickly produce prototypes, functional parts and tools. This not only saved the company hundreds of hours of time, but also gave them the ability to immediately validate the design in practice. Designers don't have to spend hours verifying in CAD, but can print and test parts straight away, speeding up development and giving designers greater design freedom.

Dozens of drilled holes

When manufacturing the XB-1, a huge number of holes need to be drilled for fasteners, which, due to the precise placement of each one, is extremely time consuming. Conventional metal drilling jigs would be very costly and delay production with long lead times. Multi-hole drilling templates printed from rigid thermoplastics, which allow dozens of holes to be drilled at once, provided the solution.

These not only delivered a 92% cost saving per drilling template compared to machining, but also reduced lead times by an average of one week. The company now has more than 700 units.

Small step for 3D printing, big leap for XB-1

Another challenge the company faced was producing a working prototype of the rudder limiter, a key element for the stability of the aircraft. Engineers needed it to test kinematics and proper function. Instead of machining it, which would have taken eight weeks and cost $12,000, Boom Supersonic printed a working prototype out of ASA thermoplastic in just 44 hours and $150.

Similarly, 3D printing also proved useful for a flight control test fixture on which engineers could test horizontal tail surfaces. Additive technologies helped reduce production from 9 weeks to 36 hours using ULTEM™ 9085 resin at a 91% cost savings.

Back pressure testing of the J85 engines was also necessary. This required fabricating the pipe from a durable material that would traditionally have been machined from aluminum blanks and took 7 weeks. Using ULTEM™ 1010 resin 3D printing, the process was reduced to 14 hours.

With this, Boom Supersonic proves that 3D printing is the key to faster and cheaper production even for complex and critical projects. This technology not only helps to shorten lead times, but also to reduce costs and respond flexibly to changes.

The future of supersonic flying

Through a combination of innovation, boldness and advanced technology, Boom Supersonic has the chance to change the face of the current aviation industry. And it's doing so with seemingly 'small' things like 3D printed templates, prototypes and jigs that actually unlock the path to new possibilities.

If the company can turn Overture into a reality, we may be able to fly at supersonic speeds more often than ever before in the near future.