From Brunei to FSWeekend: The Birth of the 3D Printed 737 Shell

New Video Out now!

It all started back in early March 2025. I received an email from a frustrated customer asking if I had ever built the 737 windows available on my website. He was struggling to achieve the correct angles and dimensions, and his tone made it clear—he wasn’t alone.

Back when I first designed those windows during my time in Brunei, I thought layering them like a 3D printer was a clever solution. It felt ingenious—simple, modular, and accessible. But reality proved otherwise. Several builders had to give up, and that feedback stuck with me.

At the time, I was preparing to demo the 737SS MIP at FSWeekend in Lelystad. That’s when a wild idea struck: what if I created the windows as a fully 3D printed structure?

I dove in headfirst. I slept beside my printers, running them non-stop to bring this concept to life in time for the expo. What emerged was a beautifully sculpted window—perfect angles, glorious curves, and a structure that turned heads at FSWeekend. The reception was incredible.

The mock-up at FSWEEKEND

This breakthrough was only possible thanks to the speed of modern printers and my years of experience in 3D printing. The goal was clear: create a window that was fast to print, strong, and easy to assemble. That’s when the idea of LEGO bricks came to mind. Each part would have a male and female connector, slotting together and held in place with screws.

Fueled by the success at FSWeekend, I spent the entire drive home—24 hours straight—thinking about how to expand this concept into a full cockpit shell. Over the past three months, I’ve done nothing but sit at my computer, designing every frame, longeron, and stringer to create what might be the world’s first fully 3D printed full-size 737 shell.

This video showcases the progress and how far this idea has come. With the help of my incredible Patreon community—affectionately called the “Printaholics”—we’re testing and refining every part to ensure it’s flawless.

The dream? To release both single and dual-seat 737 shells that anyone can build at home, packed with as much detail as my imagination allows.

This journey has been nothing short of amazing, and I’m thrilled to share it with you all. Every time I step back and look at the shell, I’m in awe. And when I step inside? I can’t help but smile.

This could be epic—and I can’t wait to create the next part!