Advancing Aerospace Interiors: Evaluation of the In-House Polymer Pellet Additive Manufacturing System

2026-26-0765

To be published on 06/01/2026

Authors
Abstract
Content
The Elektra printer is an open-source, pellet-based (FGF) 3 axis additive manufacturing system developed by Collins in collaboration with Pollen AM to enable large-scale, cost-efficient 3D printing using standard polymer pellets. In alignment with the Make in India program, Elektra represents a significant step toward localized, industrial-scale additive manufacturing that delivers affordability, flexibility, and performance for aerospace and allied industries. The system provides four major advantages. First, it enables cost-effective part production by leveraging standard injection molding grade thermoplastic pellets instead of expensive proprietary feedstocks. Second, its large build volume (800mm*800mm*400mm) supports the manufacture of tools, fixtures, and structural parts often restricted by conventional systems. Third, Elektra is compatible with a broad range of engineering and high-performance polymers that are flame retardant, ensuring adaptability for multiple use cases. Fourth, the system itself is offered at a lower acquisition cost than industry standards, making it one of the most accessible platforms in its class. Additionally, its modular design allows easy disassembly and relocation, ensuring operational flexibility and wider adoption across Collins' global sites. Elektra's high-flow extrusion system, precise thermal management, and open-architecture platform enable both R&D and production-scale applications. Of particular relevance are aircraft interior applications, including seating, lavatories, galleys, cargo systems, evacuation equipment and lighting, where light weighting, customization, and material compliance are critical. By combining affordability, scalability, and material versatility, Elektra underscores Collins' commitment to advancing accessible additive manufacturing solutions while fostering innovation under the Make in India initiative. The system exemplifies how pellet-based 3D printing can redefine cost, scale, and material performance benchmarks for aerospace and beyond.
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Citation
Kini, A. and Sundar, S., "Advancing Aerospace Interiors: Evaluation of the In-House Polymer Pellet Additive Manufacturing System," AeroCON 2026, Bangalore, India, June 4, 2026, .
Additional Details
Publisher
Published
To be published on Jun 1, 2026
Product Code
2026-26-0765
Content Type
Technical Paper
Language
English