Aerospace engineering firm triples growth with Made Smarter-backed 3D scanning investment
June 16, 2025
Airframe Designs, Blackpool, UK, has reportedly tripled in size, launched a new manufacturing division, and expanded globally after investing £40,000 in 3D scanning technology, with support from the Made Smarter adoption programme.
With a £20,000 grant from the government-backed Made Smarter adoption programme, Airframe Designs invested £40,000 in a high-tech 3D laser scanner. It enabled the business to accurately scan and reverse engineer aircraft components, assess damage, and streamline design and manufacturing processes.
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This initial investment laid the foundations for a dedicated 3D division, which has since expanded to include an advanced scanner with photogrammetry capabilities. This allowed the business to work on large-scale parts, including full airframe structures.
Jerrod Hartley, CEO of Airframe Designs, said, “The technology and innovation that the scanner brings is game-changing. The support from Made Smarter has been fantastic and really accelerated our plans. Without it, we wouldn’t be in the position we are now.”
Founded in 2009, Airframe Designs initially provided structural analysis services to the aerospace sector. A strategic shift during the pandemic saw the business diversify into manufacturing, particularly Additive Manufacturing, with a focus on offering a complete turnkey solution, from design and analysis to production.
With the introduction of scanning and digital manufacturing capabilities, the business has experienced rapid growth. Since 2022, the company’s workforce has tripled to 33, with plans to add 20 more employees within the next two years. A new manufacturing division now produces hundreds of parts per year, with ambitions to exceed 1,500 annually. Six apprentices and multiple existing staff have been upskilled in advanced scanning and additive processes.
The 3D scanning capabilities have unlocked new service areas, including the creation of complex digital twins to support structural damage assessments.
Airframe Designs is concluding a six-month project with a Middle Eastern airline to reverse engineer and manufacture cabin interior components that are no longer supported by OEMs or where it is difficult to source parts quickly and affordably.
Donna Edwards, Director of the Made Smarter Adoption Programme, said, “Airframe Designs is a powerful example of how digital technology, backed by targeted support, can drive innovation, resilience and growth in UK manufacturing. By embracing 3D scanning and Additive Manufacturing, the business has not only transformed its operations, but also created high-value jobs and opened up new global markets.”
