PSU Spacer Panel Flight-Ready Decorative Cabin Component for Boeing 777

Paradigm 3D successfully designed and manufactured a lightweight, flight-ready PSU Spacer Panel for a Boeing 777 overhead cabin interior application using ULTEM™ 9085CG. The objective was to replace a conventional interior component with an additively manufactured solution that met stringent aerospace requirements for fit, surface quality, durability, and certification readiness.

The component incorporates replaceable hinge and latch mechanisms, enabling simplified maintenance while maintaining structural integrity and aesthetic quality. Through advanced FDM manufacturing, precision post-processing, and aerospace-grade finishing, Paradigm 3D delivered an installation-ready component fully aligned with customer expectations and aviation certification standards.

The Problem

Aircraft interior components require exceptional dimensional accuracy, lightweight construction, and premium surface quality while complying with strict aerospace regulations.

The customer required a replacement PSU Spacer Panel that would:

• Maintain the original fit, form, and function.
• Reduce overall component weight without compromising strength.
• Integrate replaceable hinge and latch mechanisms for easier maintenance.
• Meet Boeing 777 cabin interior requirements.
• Achieve a high-quality decorative finish suitable for passenger cabins.
• Be prepared for certification and flight-ready installation.

Our Solution

Paradigm 3D engineered and manufactured the PSU Spacer Panel using ULTEM™ 9085CG, an aerospace-qualified thermoplastic widely recognized for its excellent strength-to-weight ratio, flame-smoke-toxicity (FST) performance, and certification suitability.

The manufacturing process included:

• Precision additive manufacturing using industrial FDM technology.
• Integration of replaceable hinges and latch assemblies.
• High-accuracy dimensional verification.
• Professional filler, primer, and aerospace paint finishing.
• Complete quality inspection and conformity documentation.
• Preparation for EASA Part 21J certification support and aircraft installation.

This approach significantly reduced manufacturing complexity while providing a lightweight, durable, and maintenance-friendly solution.

Key Results

• Flight-ready decorative cabin component for Boeing 777.
• Lightweight construction using ULTEM™ 9085CG.
• Excellent dimensional accuracy and surface finish.
• Replaceable hinge and latch design for simplified maintenance.
• High-quality aerospace paint finish.
• Improved installation efficiency.
• Certification-ready documentation package.
• Compliance with applicable aerospace interior requirements.
• Reduced lead time compared to conventional manufacturing.
• Delivered with Certificate of Conformity (CoC) and prepared for EASA Form 1 support where applicable.

Customer Benefits

• Faster replacement of aircraft interior components.
• Reduced aircraft downtime.
• Lower maintenance costs through replaceable hardware.
• Improved component lifecycle.
• Lightweight solution supporting aircraft weight reduction initiatives.
• High-quality aesthetic finish matching cabin interiors.
• Reliable production repeatability.
• Manufacturing flexibility for low-volume and replacement part production.