Stratasys Accelerates Airbus Production with Tens of Thousands of Certified 3D-Printed Parts
Airbus, in partnership with Stratasys (NASDAQ: SSYS), is revolutionizing the aerospace manufacturing landscape by producing more than 25,000 flight-ready 3D-printed parts annually, reshaping how aircraft are built, maintained, and optimized for performance across Airbus’s global fleet. Since the production of its first 3D-printed part—a spare crew seat component—Airbus has embraced additive manufacturing at scale, with over 200,000 certified polymer parts already in active service across multiple aircraft models.
This collaboration demonstrates a significant leap in efficiency, cost reduction, and sustainability, showcasing the growing role of additive manufacturing in mainstream aerospace production.
A Proven Track Record of Innovation
Airbus has leveraged Stratasys technology to integrate additive manufacturing into certified production workflows across several aircraft platforms, including the A320, A350, and A400M. Utilizing the Stratasys ULTEM™ 9085 Certified Grade (CG) filament and industrial-grade FDM® printers, Airbus has created high-performance components that meet rigorous aerospace standards.
The impact of this approach is measurable and transformative. For example, parts produced for the A350 achieved a 43% weight reduction, eliminated the need for Minimum Order Quantity (MOQ) constraints, and reduced production lead times by 85%, saving multiple weeks in manufacturing schedules while significantly lowering costs. These improvements not only enhance operational efficiency but also align with Airbus’s broader sustainability goals, including the path toward carbon neutrality by 2050.
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.
Efficiency, Flexibility, and Cost Savings
Additive manufacturing allows Airbus to produce parts on demand, closer to the point of use, which reduces inventory storage requirements, minimizes aircraft downtime, and mitigates risks associated with traditional supply chains. The ability to produce high-quality, certified parts locally and quickly enables Airbus to maintain a responsive and agile production environment, particularly critical in today’s global aerospace ecosystem.
- Faster Replacement: Parts can be manufactured as needed, reducing delays caused by supply chain bottlenecks.
- Lower Costs: The elimination of MOQs and reduced lead times cut production costs while enhancing operational efficiency.
- Weight Reduction: Lighter components contribute to improved fuel efficiency and overall aircraft performance.
This distributed production capability represents a significant departure from traditional manufacturing models, which often rely on centralized production and extensive inventories.
Impact Across Airbus Aircraft Models
The implementation of Stratasys 3D-printed parts spans multiple aircraft types. Components for the A320, A350, and A400M showcase the versatility of additive manufacturing for both structural and non-structural applications. The ability to produce reliable, lightweight, and high-performance parts ensures that aircraft operators benefit from reduced fuel consumption, enhanced performance, and lower maintenance costs.
As Airbus continues to expand its use of additive manufacturing, the technology is increasingly seen as a core enabler of production innovation, rather than a niche solution.
Stratasys: Driving Certified Additive Manufacturing at Scale
Stratasys has decades of experience serving the aerospace industry, providing additive manufacturing platforms and materials trusted by major OEMs and suppliers worldwide. Its solutions are designed to meet the most stringent aerospace standards, offering certified, repeatable parts for both production and maintenance, repair, and overhaul (MRO) applications.
Stratasys technology empowers aerospace leaders to lower operational costs, improve fleet readiness, and enhance supply chain resilience. By producing certified, flight-ready parts on demand, Airbus can respond to operational challenges faster than ever before, from emergency replacements to long-term fleet upgrades.
Sustainability and Carbon Reduction Goals
A key advantage of additive manufacturing is its contribution to sustainability. Lighter, optimized components reduce overall aircraft weight, which directly impacts fuel efficiency and carbon emissions. Airbus’s adoption of Stratasys technology aligns with its 2035 and 2050 sustainability targets, including the goal of achieving carbon-neutral operations by 2050.
By reducing waste and eliminating overproduction, additive manufacturing supports leaner manufacturing practices, ensuring that resources are used efficiently while lowering the environmental footprint of aircraft production.
Certified and Reliable Components
The success of Airbus’s additive manufacturing initiative depends on the certification and repeatability of parts. Every component produced with Stratasys technology undergoes rigorous testing to ensure compliance with aerospace standards. This level of quality assurance is crucial for flight safety, allowing operators to confidently deploy 3D-printed parts across a wide range of aircraft systems.
The ability to combine lightweight materials with structural integrity has opened the door for numerous applications, from interior cabin components to mechanical and structural parts, enhancing both passenger comfort and operational performance.
Airbus and Stratasys continue to explore new applications and materials, expanding the role of additive manufacturing in aviation. Future initiatives are expected to include:
- Broader Material Applications: Using advanced polymers and composites for more structural components.
- Global Distributed Production: Expanding production capabilities closer to assembly lines and MRO centers worldwide.
- Enhanced Design Flexibility: Leveraging 3D printing for complex geometries that are difficult or impossible to produce with traditional manufacturing.
This continued innovation is set to transform how aircraft are designed, built, and maintained, making additive manufacturing a mainstream solution for aerospace production rather than a supplemental technology.
The collaboration between Airbus and Stratasys is a clear demonstration of the transformative power of additive manufacturing in aerospace. With over 200,000 certified polymer parts in service, production efficiency gains, reduced lead times, and significant weight reductions, Airbus is not only improving operational performance but also laying the groundwork for a more sustainable, responsive, and cost-effective aviation industry.
As aerospace companies face growing pressure to reduce costs, improve supply chain resilience, and meet environmental targets, additive manufacturing provides a scalable, proven solution. Airbus’s success with Stratasys marks a pivotal moment for the industry, signaling a shift toward certified, flight-ready 3D printing as a standard production method.
This ongoing partnership highlights how innovation, advanced materials, and precision manufacturing can combine to deliver safer, more efficient, and environmentally responsible aviation solutions, setting a precedent for the future of global aerospace operations.
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