US Air Force Academy - Fortus 450mc 3D Printer

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The memorandum from the Air Force Metals Technology Office details the justification for a sole-source procurement of the Fortus 450mc and Fortus F900 Additive Manufacturing Systems manufactured by Stratasys. These systems are crucial for producing specific plastic parts used in USAF weapons systems that comply with FAA regulations regarding toxicity, flammability, and smoke. Stratasys is identified as the only vendor that can provide equipment compatible with the certified UltemTM 9085 resin, necessary for aerospace applications. The document articulates that extensive research conducted by the Product Support Engineering Division and the Metals Technology Office failed to identify any alternative additive manufacturing systems meeting the required FAA/USAF criteria. Given the aging aircraft fleet and the need for unique, low-volume parts, using Stratasys systems would avoid substantial delays and costs, which could exceed $30 million and take 5-10 years for development. The memorandum asserts that Stratasys provides adequate support, including installation, training, and warranty services, which are essential for the USAF’s implementation of additive manufacturing technologies. Overall, this procurement is framed as vital for maintaining aircraft availability and operational readiness.

This letter from Stratasys, Inc. to the Air Force Academy confirms Stratasys's ownership of over 550 patents in additive manufacturing, utilizing FDM® and PolyJet™ technologies for producing prototypes, tools, and manufactured goods from 3D CAD files. Stratasys highlights the uniqueness of their 3D printing systems due to superior print quality, accuracy, speed, and ability to print various materials simultaneously. They are the sole manufacturer and proprietor of equipment sold under FDM® and Polyjet™ trademarks and specific brands like Fortus, F-Series, J-Series, NEO, H-350, and Origin. All Stratasys equipment and materials are manufactured in Minnesota and Israel and are sold and serviced exclusively by Authorized Resellers. High Country Technology Consultants is the only authorized Stratasys Partner for the United States Air Force Academy's Mechanical Engineering department, in accordance with Stratasys's Partner Opportunity Assignment / Conflict Management Policy to ensure quality service.

The Department of the Air Force's Metals Technology Office issued a sole source justification for Stratasys Fortus 450mc and Fortus F900 additive manufacturing systems. These systems are deemed essential because they are the only equipment that meets FAA requirements for manufacturing specific plastic parts for USAF weapon systems, particularly when using Ultem™ 9085 resin. Ultem™ 9085 is the sole FAA/USAF-approved AM polymer material meeting flame, smoke, and toxicity ratings for aerospace applications and is exclusively compatible with Fortus 450mc and F900 printers. Stratasys or its approved vendors are the only providers of this equipment, compatible materials, and necessary support, including delivery, installation, training, and warranty. Research by the Air Force has not identified alternative systems that meet these strict technical requirements, and pursuing other options would cause substantial delays (5-10 years) and costs ($10-30M), impacting aircraft availability due to an aging fleet and the need for quick production of unique, low-volume parts.

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