Advanced Manufacturing

From Digital Model to Mission-Ready Component

Precision manufacturing powered by advanced materials, engineering insight, and data-driven validation.

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Our End-to-End Workflow

At ProtoAero, precision starts long before the first layer is printed.

Our fully integrated workflow—designed by engineers for engineers—ensures every part meets aerospace-grade expectations for accuracy, strength, and consistency.

01.

Design & Engineering Support

We collaborate with your team from concept to CAD refinement, ensuring your design is optimized for additive manufacturing (DfAM) and ready for high-performance production.

Capabilities include:

  • Design for Additive Manufacturing (DfAM) optimization

  • CAD modeling and geometry analysis

  • Lightweighting and topology optimization

  • Assembly consolidation and tolerance design

  • Functional prototyping for fit, form, and flow

Result: Fewer iterations, lower costs, and parts engineered for maximum performance.

02.

Additive Manufacturing

Our advanced additive systems deliver tight tolerances, fine surface detail, and production-grade mechanical properties.

We use industrial-grade machines capable of handling complex geometries and high-performance materials.

Core 3D Printing Technologies:

  • FDM (Fused Deposition Modeling) – functional prototypes and production tooling

  • SLS (Selective Laser Sintering) – Coming Soon

  • SLA (Stereolithography) – Coming Soon

Machine Highlights:

  • EOS P 396 (SLS)

  • HP Jet Fusion 5200 Series (MJF)

  • Stratasys Fortus 450mc (FDM)

  • Formlabs Form 3L (SLA)

03.

Subtractive Manufacturing

We’ve expanded our capabilities beyond additive—introducing Milo CNCs to the ProtoAero production fleet.

Our 3-axis and 4th live-axis CNC machines allow for high-precision subtractive manufacturing, ideal for components requiring tight tolerances, clean surface finishes, or hybrid manufacturing workflows.

Capabilities include:

  • CNC machining for metals and engineered plastics

  • Complex contouring and multi-face operations

  • Rapid jig and fixture production

  • Hybrid manufacturing: Additive + Machining integration

  • Tolerances as tight as ±0.025 mm

Combining digital precision with the craftsmanship of CNC machining ensures your parts meet the strictest engineering and performance requirements.

04.

Advanced Materials

We print with aerospace-grade polymers and composites engineered for high-stress, high-temperature environments.

Performance Materials Include:

  • PEEK / ULTEM 9085 – Coming Soon

  • Nylon 12 / PA12 – excellent mechanical stability, ideal for production runs

  • Carbon Fiber-Reinforced Nylon – lightweight, rigid, and ideal for structural parts

  • ABS / ASA – durable prototypes with good impact strength

  • Resins (Standard, Tough, Clear, High-Temp) – for fine detail and visual models

Don’t see your preferred material? We support custom-sourced polymers and can evaluate performance requirements upon request.

05.

Post-Processing & Finishing

Your project doesn’t end when printing stops.

We provide in-house finishing and validation services to ensure every component looks, fits, and performs exactly as intended.

Capabilities:

  • Dimensional inspection and measurement verification

  • Surface finishing (sanding, vapor smoothing, coating)

  • Dyeing and color finishing

  • Threading, inserts, and machining for functional assembly

  • Assembly and fit testing

Precision isn’t just about tolerances—it’s about the final feel, function, and fit.

06.

Quality & Validation

ProtoAero operates to aerospace-grade standards, applying rigorous data-driven validation at every stage.

Our quality process includes:

  • Dimensional analysis and geometric verification

  • Laser scanning and 3D metrology

  • Material traceability and batch documentation

  • Controlled environmental printing and post-processing

  • Repeatability testing for small-batch production

Tolerances:

  • Standard: ±0.1 mm or ±0.1% (whichever is greater)

  • High-precision builds: down to ±0.05 mm, depending on geometry and material

07.

Small-Batch & Production Manufacturing

When your prototype is ready for the real world, we scale production seamlessly.

Our manufacturing systems are optimized for low-to-mid volume runs, ensuring consistency across every unit.

Production capabilities:

  • Multi-part nesting for efficient batch printing

  • Repeatable calibration and quality tracking

  • Serialized part labeling and packaging

  • Rapid replenishment for ongoing production cycles

From prototype to production, our systems ensure each part performs as designed—every time.

Precision 3D Printing for Aerospace and Beyond

Rapid prototyping, small-batch production, and end-to-end engineering—all under one roof in Toronto.

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Why Choose ProtoAero

  • A target with concentric circles and an arrow hitting the bullseye.

    Aerospace-Grade Precision

    Tight tolerances. Critical geometries. Every part meets the highest industry expectations.

  • Icon of a stopwatch with an orange background.

    Rapid Turnaround

    From design to delivery, we cut lead times by up to 50% compared to traditional processes.

  • Flowchart with three rectangular boxes connected by lines, leading to a circle with a check mark inside.

    Integrated Design-to-Production Workflow

    We don’t outsource your project. In-house engineers manage everything from CAD validation to final post-processing.

  • Three cubic boxes stacked, with the top box highlighted in orange.

    Advanced Materials Expertise

    High-performance polymers and composites built for heat, stress, and wear—because your parts aren’t decorative.

  • Loading screen with an orange background and a black dotted circle in the center.

    Data-Driven Manufacturing

    Our process isn’t guesswork. It’s measurement, iteration, and precision you can prove.

Ready To Move From Prototype To Production?

Get expert insights and a tailored quote—fast.

Request a Quote

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