Airbus to Receive 3D-Printed Fuselage and Engine Pylon Parts from Alcoa

Despite enthusiasm, the role of additive manufacturing in aerospace industry remains unclear.

Close up of an engine and pylon. (Image courtesy of Airbus.)

Close up of an engine and pylon. (Image courtesy of Airbus.)

Airbus has entered into an agreement with Alcoa for the supply of 3D-printed titanium fuselage and engine pylon components for Airbus commercial aircraft.

Alcoa credits its recent acquisition of RTI International Metals—now known as Alcoa Titanium & Engineered Products—as one of the driving factors behind the agreement. The RTI acquisition enabled Alcoa to add titanium to its metal additive manufacturing (AM) capabilities.

Alcoa reports that it will employ CT scanning and hot isostatic pressing (HIP) at its aerospace facility to produce the parts, along with titanium ingot melting and billetizing, machining and finishing.

The use of HIP indicates that Alcoa will only use AM for the near net shape of the fuselage and engine pylon parts, rather than 3D printing the parts in a single step.

However, the company also recently invested USD$60 million in 3D-printed materials and processes, including metal powders.

3D-printed titanium bracket for A350 XWB aircraft. (Image courtesy of Airbus.)

3D-printed titanium bracket for A350 XWB aircraft. (Image courtesy of Airbus.)

Airbus has been working to expand its use of 3D-printed parts since 2014, when the company started using 3D-printed titanium brackets in A350 XWB aircraft. In addition to using 3D-printed parts from its suppliers, the company is also investigating using AM to avoid outstanding work during the manufacturing process.

“Each time we have a missing part at assembly level it causes a significant disturbance and costs money for us to recover. AM can be used to manufacture missing and non-standard parts fast in low quantities,” said Bernard Duprieu, manufacturing engineer with Airbus’ Research and Technology team.

Duprieu and his team are currently developing an AM workshop that can produce customized parts in under 24 hours.

The extent to which OEMs like Airbus will adopt AM into their own production lines remains uncertain, especially when Tier 1 suppliers like Alcoa are willing to shoulder the risk for them. Nevertheless, with Alcoa joining the likes of General Electric in investing in metal additive manufacturing, we should expect to see more 3D-printed parts taking flight soon.

The precise details of the agreement have not been disclosed, but Alcoa did report that the first 3D-printed parts will be delivered by Airbus in mid-2016.

For more information, visit the Alcoa website.

Written by

Ian Wright

Ian is a senior editor at engineering.com, covering additive manufacturing and 3D printing, artificial intelligence, and advanced manufacturing. Ian holds bachelors and masters degrees in philosophy from McMaster University and spent six years pursuing a doctoral degree at York University before withdrawing in good standing.