The idea to incorporate 3D printing came from CEO Vlado Pekár, who has used the technology for over a decade for prototyping and proof-of-concept. Over 100 components of the Shark, including cockpit parts and those near the engine, are 3D printed using materials like Prusament ABS for thermal resistance and Prusament PA11 (nylon) for high-heat areas near the engine.
Functional parts like covers, holders, hooks, control grips, and landing gear doors are 3D printed, with the latter adding 10 kilometers of speed to the aircraft through innovative design iterations. SHARK.AERO estimates that 3D printing saves approximately 100 work hours per plane, totaling 300–400 hours monthly. The company also uses 3D printing to test molds for carbon composite parts, printing initial molds in PLA for testing before serial production.
Revolutionizing Aviation Manufacturing
SHARK.AERO relies on Original Prusa 3D printers, including the MK4, for their durability, reliability, and print quality. These printers enable scalable production without sacrificing quality. By combining 3D-printed parts with custom carbon components, SHARK.AERO achieves both efficiency and innovation in their manufacturing process.
A 3D-printed control grip for the Shark cockpit.
3D-printed landing gear door enhancing aircraft speed.
A PLA mold prototype for carbon composite parts.
Every plane has more than 100 3D-printed parts under the hood.
SHARK.AERO is a Czechoslovak manufacturer of full composite airplane SHARK and composite aircraft parts. The company has a rich history spanning over 30 years: They initially started as a parts producer for Diamond Aircraft, but over time, they established their own brand – the Shark. The Shark is the fastest ultralight aircraft in the world and helped its pilots achieve several Guinness world records.
