When technology partners with creativity, it often leads to exciting projects – as demonstrated by Xavier Thomi, who, besides training at Pilatus, is an enthusiastic user of 3D printing. What began out of curiosity has become a hobby which delivers real practical added value – in Xavier’s private life as well as in his day-to-day work.
“I’ve always loved bringing things to life with my own hands – and lots of technology,” says Xavier. He became interested in 3D printing when he first moved into an apartment with his girlfriend. “New surroundings, lots of ideas and, at last, an excellent reason to go ahead with a long-held wish – to buy my own 3D printer.” Suffice to say that Xavier had scarcely taken the printer out of its box before he had already printed his first small model – he was hooked! With growing experience, Xavier was soon aiming for more ambitious things. These days, he works with a far more sophisticated machine – and 3D printing has long progressed beyond the stage of a technical toy. “It’s much more than a hobby, it’s become a real passion!”
Practical ideas for day-to-day work
Most of all, Xavier enjoys printing functional components designed to solve specific problems. He’s particularly proud of one project which originated directly at Pilatus: creating an adapter for ground studs – a small tool which makes it easier to assemble electrical connection elements in hard-to- reach locations. “I developed the first versions using 3D printing, tested them in my day-to-day work and then optimized them further as needed.” The mature design is now made from tool steel and is used in production operations at Pilatus. Xavier regularly finds opportunities to apply his expertise to his day-to-day work – be it for cable protectors, special tools or ratchet covers to prevent structural damage. “That’s exactly where I see the greatest strength of 3D printing: in custom solutions when standard products aren’t enough.”
Xavier is currently working in the “Weisshorn” Hall with the wing integration team as part of his training to become a Technical Specialist at Pilatus. Precision and teamwork are immensely important: “The opportunity to combine technology, aviation and teamwork is an aspect of my work which I really enjoy. It makes me proud to be involved with a product that will ultimately take to the skies.”
Creative freedom and technical rigor
What is it about 3D printing that fascinates Xavier in particular? The speed and flexibility. “I often design parts digitally, on the computer, and the next morning the first prototype appears on my desk, fresh out of the printer.” He is particularly excited about the wide choice of materials available – from simple plastics for home use to especially robust and flexible variants suitable for heavy-duty applications.
One particularly complex project was a self-designed operating panel for his flight simulator – with switches, controls and LEDs. “The planning, construction, electronics and countless hours of printing made this project a real challenge – but the results speak for themselves.”
Technology also takes up a good part of his free time. He plays around with new ideas, flies virtual routes in his simulator or devotes himself to photography. “For me, photography provides the perfect balance. It naturally combines technology, creativity and an eye for detail.”
Xavier appreciates the way his hobby dovetails with his work. “At work, it doesn’t take long to see where there’s room for improvement and innovation. And 3D printing helps me to take a more creative, flexible approach to technical problems.” There is no question in his mind that 3D printing will play an increasingly important role in aviation – particularly for prototypes or custom parts with special requirements.
For the time being, Xavier isn’t dreaming of anything specific in terms of what he would like to print in the future: “I’m attracted to any new projects that challenge me, or present an opportunity to improve something. I love being involved in anything where I can learn something new and make things easier for someone.”
The adapter facilitates installation of the ground stud without damaging the structure.
Xavier printed this cover from flexible plastic to better protect the structure from scratches and knocks.
Hot off the 3D printer – an edge protector to prevent damage to fragile cables.
The 3D printer makes Xavier feel like he can really design something useful, rather than just tinkering.
A self-built operating panel for Xavier’s flight simulator.
