How does replacement of traditional production with polymer additive manufacturing affect aircraft production costs and schedules today? A decisive response comes from Airbus, with production of more than 25,000 ready-to-fly 3D printed polymer components every year with its Stratasys industrial-grade FDM 3D printing solutions and ULTEM 9085 Certified Grade materials. Large-scale additive production that could be considered R\&D projects some years ago today integrates with airplane production and maintenance operations at Airbus on A320, A350, and A400M airplane models.
It began with limited volumes, with a single spare crew seat being the first polymer-based component made with 3D printing, or AM. Today, Airbus boasts more than 200,000 qualified 3D-printed polymer components flying on aircraft. Featured applications include internal assemblies, helicopter components, and flexible shafts – all qualified to aerospace standards. The learning curve has been short due to demands for lighter weight, shorter production times, and a more flexible supply chain.
Regarding the A350 aircraft program, it should be noted that there is measurable performance enhancement on this project. According to information from Airbus, there is a 43% reduction in part weight as well as an 85% reduction in lead times associated with 3D printing of approved components. Elimination of Minimum Order Quantity requirements has also made it easier, as components can be made when they are required and without having to deal with heavy inventory costs.
Serge Senac, the Airbus Industrial Leader for Polymer Additive Manufacturing, appreciated the importance of this technology: Stratasys additive manufacturing technology plays a critical role in our efforts at Airbus to support a sustainable and safe aviation transport sector. We have the capability today to manufacture qualified and repeatable components quicker without being dependent on intricate supply chains. Moreover, it will allow us to be more flexible and maintain low costs and a rapid response times, addressing customer needs worldwide. Not to mention that it will also help us achieve our commitment to be carbon neutral by 2050.
Distributed manufacturing plays an integral role here. Airbus uses distributed manufacturing to produce aircraft components closer to where they will be used. By doing so, aircraft downtimes are reduced, and storage as well as the associated logistical challenges associated with global supply chain cycles are eliminated. It should be noted that a similar strategy drives efforts within the defense industry, for instance, within Project TAMPA, wherein distributed AM and rapid certification techniques are being designed so as to maintain operational readiness even with stress on the supply chain.
It should be noted that the materials basis on which Airbus’ plan for polymer-based AM is founded ULTEM 9085 Certified Grade in itself boasts excellent strength-to-weight ratio, flame resistance, and aerospace industry compliance. All these characteristics make it possible for these components to qualify under demanding qualification procedures and thus assist in ensuring that safety and reliability are not degraded with the transition to AM. At the same time, Airbus works on more visionary projects involving systems enabled with AM, with a focus on hydrogen-electric propulsion and heat exchangers.
Rich Garrity, Chief Business Unit Officer at Stratasys, emphasized broader implications for the industry: “Our collaboration with Airbus is proof that additive manufacturing is being integrated into true production at scale, and can be a huge differentiator.” Seeing tens of thousands of validated airframe components flying commercially today speaks volumes about an industry shift and not just for Airbus. The market for lighter, faster, and more agile supply chains is driving adoption of our technologies globally. It’s an indication that what Airbus is doing today marks a start to a next phase and growth period for our industry. That next phase will be mainstream adoption and certification of additive methods within aviation. By incorporating qualified polymer-based Additive Manufacturing within its production and maintenance infrastructure, Airbus shows that Additive Manufacturing can offer both cost and business benefits at an aircraft fleet level. Weight reduction, lead-time reduction, and the possibility of local production make it increasingly central to next-generation aircraft production.