Using heavily filled composite stereolithography resins from DSM Somos, Italian rapid prototyping service bureau Provel has developed a scaled prototype of the M-346 fighter trainer aircraftfor Alenia Aermacchi. The M-346 represents a new generation of advanced fighter trainer. Including a variety of unconventional attributes, advanced technologies and avionics, the M346 features superior performance. Essential to the development process was the creation of an accurate, scaled prototype for wind tunnel testing.

Based on the inherent complexity of the prototype design, Provel chose to produce the model using the DSM Somos composite stereolithography resin ProtoToolT 20L, rather than the powder sintering technique. Belonging to the Somos family of ProtoCompositesT materials, ProtoToolT 20L is a ceramic-filled resin producing highly stiff and accurate parts. With a modulus of 10,000 MPa, a linear shrinkage of 0.025 mm, and a heat-deflection temperature (HDT) of 279 °C, ProtoToolT and the commercialized NanoToolT have become resin choices in wind tunnel test applications.

The dimensions required for the scaled model of the M-346 were 1000 mm × 1000 mm × 200 mm. Because some parts were larger than stereolithography equipment will permit, the model was constructed in several pieces and then assembled. An important advantage provided by the ProtoCompositesT material during development of the model was the time and cost savings. As a result, the final cost analysis on producing the M-346 model with ProtoToolT demonstrated a cost savings of more than 30%.

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