Airbus Pioneers New Era of Aircraft Production with Titanium 3D Printing

The global manufacturer Airbus is advancing aircraft manufacturing innovation.

They are incorporating titanium 3D printing technology into production. This shift is changing how titanium structural components are made. The goal is to build airliners more efficiently.

The Wire-DED Technology

Airbus is focusing on wire-Directed Energy Deposition (w-DED). This is an advanced form of additive manufacturing aerospace technology. It uses a robotic arm and titanium wire. An energy source, like a laser, melts the wire. This process builds the part layer-by-layer.

This method is fundamentally different from traditional forging. Forging carves parts from large metal blocks. The w-DED process creates a "near net shape" blank. This blank is very close to the final design.

Reducing Material Waste and Cost

The primary benefit is a significant reduction in less material waste. Traditional subtractive methods are inefficient. They can result in 80% to 95% of the titanium being recycled.

Titanium is an expensive and high-value material. The w-DED process prevents most of this waste at the source. This leads to immediate, real-world cost savings.

This technology also speeds up production timelines. Traditional die forging can require complex tooling. This tooling may take up to two years to create. The new 3D-printed part shape is computer-determined. This reduces the lead time to just a few weeks.

Scaling Up Structural Components

Previous metal 3D printing focused on small components. These parts were often less than two feet long. The w-DED technique scales the process dramatically. It allows Airbus to produce titanium structural components up to seven meters (23 feet) long.

This scale makes additive manufacturing aerospace viable for primary structures. The process is also faster than older powder-bed methods. It boosts production rates to several kilograms per hour.

Current Applications and Future Plans

Airbus has already begun integrating these large w-DED parts. They are in use on the A350 aircraft. Specifically, they are used in the Cargo Door Surround area.

These 3D-printed components are functionally identical to forged parts. They offer the same strength and fatigue resistance.

Looking ahead, Airbus plans to expand w-DED usage. The technology will move to more critical applications. This includes parts for wings and landing gear in the longer term.

Certification and Industry Trust

Introducing new future aircraft production methods requires regulatory approval. The European Union Aviation Safety Agency (EASA) is actively involved. They provide guidance on certifying additive manufacturing technologies.

Certification focuses on process control and data collection. This ensures the new titanium alloy parts meet strict safety standards. The industry is working step-by-step toward full adoption of AM for primary structures.

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