Fuel tank simulation will help validate new satellite design

MINNEAPOLIS — (BUSINESS WIRE) — April 30, 2014 — RedEye, by Stratasys (Nasdaq: SSYS), one of the world’s leading additive manufacturing service bureaus, recently partnered with Lockheed Martin’s Space Systems Company (SSC) to 3D print two large fuel tank simulators for a satellite form, fit and function validation test and process development. With the biggest tank measuring 15 feet long, the project marks one of the largest 3D printed parts RedEye has ever built.

With RedEye’s Fused Deposition Modeling (FDM) technology, the team developed the fuel tanks within a highly condensed time frame and at about half the cost of machining the parts. These rapid prototyping advantages will help Lockheed Martin bring its new design to market faster in a competitive contract bid process.

“With RedEye’s machine capacity and engineering support, we were able to successfully build these tank simulators in a fraction of the time and at a fraction of the cost,” said Andrew Bushell, senior manufacturing engineer at Lockheed Martin Space Systems Company.

The larger tank was built in 10 different pieces and the smaller in 6 different pieces using polycarbonate (PC) material. Combined, the fuel tanks took nearly two weeks to print, taking roughly 150 hours per section. Based on the sheer size of the parts, customized fixtures were required to support the structures as they were bonded together and shipped to be machined to meet specifications. Once all of the pieces were machined, the final assembly required 240 hours.

“This project is unique in two ways – it marks the first aerospace fuel tank simulation produced through additive manufacturing and is one of the largest 3D printed parts ever built,” stated Joel Smith, strategic account manager for aerospace and defense at RedEye. “Our ability to accommodate such a large configuration and adapt to design challenges on the fly, demonstrates that there really is no limit to the problem-solving potential when you manufacture with 3D printing.”

Lockheed Martin first embraced the design benefits of additive manufacturing with RedEye in 2012 and has invested in in-house 3D printers from RedEye’s parent company, Stratasys. RedEye has worked with Lockheed Martin on various tooling and additive manufacturing projects that support its Space Systems Company. The organizations are expected to partner on more 3D printing projects later this year.

For more details about RedEye’s largest-ever 3D build, read the case study.

About RedEye

RedEye, a business unit of Stratasys, is one of the world’s largest providers of rapid prototyping and additive manufacturing services. The company leverages Stratasys’ patented FDM and PolyJet 3D printing technologies to assist companies in all phases of product development from conceptual modeling to the production of end-use parts. RedEye has a network of more than 150 3D printers worldwide and has received awards for its services and leadership. Online at: RedEyeOnDemand.com.

About Stratasys

Stratasys Ltd. (Nasdaq: SSYS), headquartered in Minneapolis, Minn. and Rehovot, Israel, is a leading global provider of 3D printing and additive manufacturing solutions. The company's patented FDM® and PolyJetTM 3D Printing technologies produce prototypes and manufactured goods directly from 3D CAD files or other 3D content. Systems include 3D printers for idea development, prototyping and direct digital manufacturing. Stratasys subsidiaries include MakerBot and Solidscape, and the company operates the RedEye digital-manufacturing service. Stratasys has more than 1800 employees, holds over 550 granted or pending additive manufacturing patents globally, and has received more than 25 awards for its technology and leadership. Online at: www.stratasys.com or http://blog.stratasys.com.

Cautionary Statement Regarding Forward-Looking Statements

Certain information included or incorporated by reference in this press may be deemed to be “forward-looking statements” within the meaning of the Private Securities Litigation Reform Act of 1995, Section 27A of the Securities Act of 1933, and Section 21E of the Securities Exchange Act of 1934. Forward-looking statements are often characterized by the use of forward-looking terminology such as “may,” “will,” “expect,” “anticipate,” “estimate,” “continue,” “believe,” “should,” “intend,” “project” or other similar words, but are not the only way these statements are identified. These forward-looking statements may include, but are not limited to, statements relating to the company’s objectives, plans and strategies, statements regarding the performance of our products, statements that contain projections of results of operations or of financial condition (including, with respect to the MakerBot acquisition) and all statements (other than statements of historical facts) that address activities, events or developments that the company intends, expects, projects, believes or anticipates will or may occur in the future. Forward-looking statements are not guarantees of future performance and are subject to risks and uncertainties. The company has based these forward-looking statements on assumptions and assessments made by its management in light of their experience and their perception of historical trends, current conditions, expected future developments and other factors they believe to be appropriate. Important factors that could cause actual results, developments and business decisions to differ materially from those anticipated in these forward-looking statements include, among other things: the company’s ability to efficiently and successfully integrate the operations of Stratasys, Inc. and Objet Ltd. after their merger as well as MakerBot after its acquisition and to successfully put in place and execute an effective post-merger integration plans; the overall global economic environment; the impact of competition and new technologies; general market, political and economic conditions in the countries in which the company operates; projected capital expenditures and liquidity; changes in the company’s strategy; government regulations and approvals; changes in customers’ budgeting priorities; litigation and regulatory proceedings; and those factors referred to under “Risk Factors”, “Information on the Company”, “Operating and Financial Review and Prospects”, and generally in the company’s annual report on Form 20-F for the year ended December 31, 2013 filed with the U.S. Securities and Exchange Commission and in other reports that the company has filed with the SEC. Readers are urged to carefully review and consider the various disclosures made in the company’s SEC reports, which are designed to advise interested parties of the risks and factors that may affect its business, financial condition, results of operations and prospects. Any forward-looking statements in this press release are made as of the date hereof, and the company undertakes no obligation to publicly update or revise any forward-looking statements, whether as a result of new information, future events or otherwise, except as required by law.