Stratasys, a U.S.-based manufacturer of polymer 3D printing systems, is powering Airbus production of more than 25,000 flight-ready components each year. The aircraft maker, which first adopted additive manufacturing for a spare crew seat component, now has over 200,000 certified Stratasys polymer parts in service across its global fleet. This large-scale integration marks one of the most advanced industrial uses of additive manufacturing in aviation.
Data from the manufacturer shows that the use of 3D printed components on its A350 aircraft has resulted in a 43% weight reduction, the removal of Minimum Order Quantity (MOQ) constraints, and an 85% cut in lead time. These outcomes have translated into significant cost savings and shorter production cycles. Components for the A320, A350, and A400M are produced using Stratasys ULTEM 9085 Certified Grade (CG) filament on the company’s industrial FDM printers. The thermoplastic material, known for its high strength-to-weight ratio and flame, smoke, and toxicity compliance, meets the rigorous certification standards required in aerospace manufacturing.
“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.”
Certified polymer materials and hardware enable Airbus to manufacture parts that comply with stringent safety and performance regulations while maintaining production flexibility. Distributed manufacturing further allows printing near points of use, reducing aircraft downtime, minimizing inventory, and mitigating supply chain bottlenecks. These efficiencies have become increasingly relevant as aerospace companies adapt to fluctuating logistics and maintenance demands following global supply chain disruptions.
Rich Garrity, Chief Business Unit Officer at Stratasys, said the collaboration reflects a key inflection point for additive manufacturing in aviation. “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,” he said. “Demand for lighter, faster, and more resilient supply chains is accelerating the 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.”
The additive manufacturing firm has spent decades developing high-performance thermoplastics and validating digital production methods for flight-critical applications. Its ULTEM 9085 CG material, produced under strict traceability protocols, is designed for both production and maintenance, repair, and overhaul (MRO) operations. These applications reduce reliance on legacy tooling, support rapid replacement of cabin and structural components, and extend aircraft service life while maintaining regulatory compliance.
Airbus’s long-term adoption of additive methods signals how 3D printing has transitioned from prototyping to production. Incorporating polymer additive manufacturing across multiple aircraft programs demonstrates how certified digital fabrication can shorten lead times, increase supply chain resilience, and help reduce environmental impact.
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Featured image shows Airbus A400M military transport aircraft. Photo via Airbus.
