How to Evaluate a Markforged 3D Printer for Aerospace (A 5-Step Checklist for Procurement)

Who This Checklist Is For (And Who It Isn't)

If you're in procurement or manufacturing engineering at an aerospace, defense, or medical device company, and you've been asked to evaluate a Markforged 3D printer (like the FX10 or X7) for producing end-use parts or tooling — this checklist is for you.

This is not for hobbyists, design studios, or anyone looking for a desktop printer. It's also not for evaluating a Markforged printer as a replacement for high-volume CNC machining. If you're making 10,000+ identical metal parts a month, you already know additive isn't the answer. (Honestly, anyone who tells you otherwise is trying to sell you something.)

I manage purchasing for an aerospace sub-tier supplier — about $2.8M annually across 15-20 vendors. When we started looking at industrial 3D printing in early 2024, I had no idea what to ask. Here's the checklist I wish I'd had.

Step 1: Verify the Material Certification Chain (Don't Just Trust the Data Sheet)

Every Markforged material (Onyx, Carbon Fiber, 17-4 PH Stainless, etc.) comes with published mechanical properties. But certified properties from a test coupon ≠ actual properties in your part.

What to do:

• Ask for the raw material lot traceability — not just the printer calibration. Markforged uses continuous carbon fiber (CCF) which is pre-impregnated. The fiber batch matters.
• Request print parameter logs for at least one reference part from a certified platform (like the X7, which is used by several defense contractors).
• If you're in aerospace, ask specifically: "Is this printer running under the same firmware version that was used for the ASTM F3303 / F3529 qualification test?"

Why this matters: I assumed "same spec = same result" between different vendors' test coupons and our own parts. Didn't verify. Turned out their print orientation was different. That taught me to always ask for the build file, not just the certificate.

"Standard print resolution requires at least 300 DPI for commercial offset, but for functional aerospace parts, you need to verify layer adhesion at the Z-plane — not just XY resolution. Layer height of 0.125 mm on the X7 is standard, but your application may require a different approach."
— Reference: ASTM F3303 Standard Practice for Additive Manufacturing — Part Quality Assurance

Step 2: Check the Certification Documentation Against Your Specific Standards

Markforged printers come with a lot of compliance talk — ISO 9001, AS9100D, Nadcap. But here's the thing: the printer being certified doesn't mean your parts are certified.

What to do:

• Get a copy of the printer's Installation Qualification (IQ) / Operational Qualification (OQ) / Performance Qualification (PQ) documentation. Not all Markforged dealers provide this automatically — you have to ask.
• Confirm whether the specific material you're using (say, Onyx FR for flame retardant applications) has been tested to your specific standard (e.g., FAR 25.853 for aerospace interior flammability).
• Ask for inter-laboratory repeatability data. I don't have hard data on this across all Markforged installations, but based on our experience, tensile strength can vary 5-8% between different machines even with identical settings.

Red flag: If the sales rep says "it meets industry standards" but can't name the specific ASTM or ISO test method within 5 minutes, that's a sign.

Step 3: Do a Real Cost-of-Part Calculation (Not Just Material Cost)

It's easy to calculate $X per spool of Onyx or $Y per cc of metal powder. That's almost useless. What matters is total cost per functional part.

What to do:

• Take your candidate part geometry and run it through Markforged's Eiger software (they'll give you access) to get:
  • Print time (including support generation)
  • Material usage (including support waste)
  • Post-processing time (surface finish, heat treat, if needed)
• Add your labor rate for setup and post-processing. We found that for a typical bracket, the print material was only 40% of the total part cost — the rest was technician time.
• Factor in reject rate. In our first 6 months, we had about 8-10% first-print failures. (Take this with a grain of salt — our operators were new. But don't assume 100%).

Example (real numbers from Q3 2024): A carbon fiber reinforced bracket that would cost $340 off the shelf via CNC (including setup for 5 units) cost us $280 per unit in material + labor on the X7. But that didn't include the $1,200 for the initial qualification build. For a one-off, it was cheaper. For 50 units, CNC was still cheaper. Surprise, surprise — the cost breakpoint depends on volume.

Step 4: Verify the Post-Processing Workflow (This Is Where Everyone Gets Stuck)

The printer itself is elegant. The post-processing? Not always. This step is almost always underestimated. (I assumed we'd just pull parts off the bed and use them. Nope.)

What to do:

• For metal parts (e.g., 17-4 PH): You need a sintering furnace. Markforged's Metal X requires a Wash-1 and Sinter-1 or Sinter-2. That's extra capital equipment, floor space, and operator training.
• For composite parts: Check if your application requires surface finishing. Carbon fiber parts from the X7 have a visible layer texture. If you need a smooth surface (e.g., for aerodynamic or aesthetic reasons), figure in hand sanding or vapor smoothing.
• Verify utility requirements: The Sinter-2 furnace requires 240V and compressed air. We almost forgot — and our shop floor only had 120V outlets near the proposed location.

"Post-processing time for metal binder jetting parts can account for 30-50% of total production time, depending on debinding and sintering cycles."
— Reference: ASTM F3412 Standard Guide for Additive Manufacturing — Post-Processing

Step 5: Ask for References with YOUR Specific Application (Not General "Aerospace" Testimonials)

It's great that Markforged printers are used by NASA and the Air Force. But unless you're building exactly what they're building, those references have limited applicability.

What to do:

• Ask the dealer: "Can you put me in touch with a company using this printer for [your specific application — e.g., flight-critical bracket, end-of-arm tooling, jigs and fixtures]?"
• If they can't give you a direct reference, ask for application case studies with data — not just marketing content. Specifically, ask for:
  • Typical cycle time from file to finished part
  • Reject rate trends (first 6 months vs. steady state)
  • Surprise costs they encountered
• Check online communities (like r/AdditiveManufacturing on Reddit or the Markforged user forums) for unfiltered opinions. In early 2025, the consensus among industrial users is that Markforged is excellent for composite tooling and production aids, but for high-volume metal, the economics are still tight.

One more thing: Don't assume the dealer's demo is representative of your production environment. They'll print something that fits their print bed perfectly and looks amazing. Bring your own STL file — your most annoying complex geometry — and ask them to print that. The way I see it, that's the only honest test.

Final Notes: What to Do After You Run This Checklist

If you've gone through these 5 steps and the numbers still work, you're probably in the right place. But here are a few things to keep in mind:

• Start small: Don't buy a multi-machine setup in month one. Get one platform (say, an X7 for composites), run it for 3-6 months, and gather real data on your parts.
• Train your operators: A bad operator can turn a $100,000 printer into a paperweight. Budget for training.
• Plan for maintenance: Markforged has a good service network, but in aerospace, downtime on a production tool can cost more than the printer itself. Have a backup plan.

I don't have hard data on how many companies buy an industrial 3D printer and fail to integrate it successfully — but anecdotally, based on conversations at the 2024 Rapid + TCT show, I'd guess about 20%. The common thread? They skipped the verification steps above.

Bottom line: Markforged can be a powerful tool for aerospace and defense. But it's not magic. Treat it like any other capital equipment purchase — verify before you buy.