Airbus is increasingly relying on additively manufactured plastic components for the construction and maintenance of its aircraft. Based on Stratasys systems, more than 25,000 flight-ready 3D-printed parts are now produced per year according to the company, and more than 200,000 certified components are already in service across the fleet. What began with a replacement part for a crew seat has become an integral element of the production and MRO (Maintenance, Repair and Overhaul) processes.
“Stratasys’ additive manufacturing technology is an integral part of our commitment to safe and sustainable aviation,” said Serge Senac, Airbus Industrial Leader for Polymer Additive Manufacturing. “We can produce certified, repeatable parts faster, with less reliance on complex supply chains. This manufacturing flexibility reduces costs and ensures improved response times to meet the needs of our customers around the world. Last but not least, this technology contributes to Airbus’ roadmap to achieving carbon neutrality by 2050.”
From a technical standpoint, Airbus relies on industrial FDM systems from Stratasys that process the flame-retardant high-performance thermoplastic ULTEM 9085 in its certified-grade variant. The material meets aerospace requirements for strength, temperature resistance, and flame, smoke and toxicity performance. Parts are printed for the A320, A350 and A400M programs, including cabin components and function-integrated brackets. For the A350, Airbus reports a weight reduction of 43 percent compared to conventionally manufactured parts. At the same time, minimum order quantities are eliminated, and lead times are reduced by around 85 percent according to current data, saving several weeks in the supply chain.
“Our collaboration with Airbus is proof that additive manufacturing is being integrated into true production at scale, and can be a huge differentiator,” said Rich Garrity, Chief Business Unit Officer, Stratasys. “With tens of thousands of certified parts already flying, we are seeing an inflection point, not just for Airbus, but for the entire aerospace industry. Demand for lighter, faster, and more resilient supply chains is accelerating, adoption of Stratasys technology worldwide. What Airbus is achieving today signals the next growth chapter for our industry: certified additive manufacturing as a mainstream production method across aviation globally.”
In the long term, Airbus is embedding 3D printing into its sustainability strategy. Lighter components reduce fuel consumption, and shorter supply chains reduce indirect emissions. Overall, the program indicates that certified polymer additive manufacturing is evolving from isolated use cases into a standard production process in commercial aviation.
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