Powered by Stratasys technology, Airbus is producing more than 25,000 flight-ready 3D-printed parts annually, transforming how aircraft are built and maintained across its global fleet. Evolving from its first part, a spare crew seat component, Airbus has embraced additive manufacturing, taking it to new heights with more than 200,000 certified Stratasys polymer parts now in active service.

Recent data shows that the implementation of Stratasys’ 3D printed parts utilized in the Airbus A350 resulted in a 43 percent weight reduction, the elimination of the Minimum Order Quantity (MOQ) requirement, and an 85 percent reduction in lead time, saving significant cost and multiple weeks of production time. Airbus has parts printed for the A320, A350, and A400M models using the Stratasys ULTEM 9085 filament Certified Grade (CG) material on multiple Stratasys industrial-grade FDM printers.

“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.”

These parts meet rigorous aerospace requirements while enabling faster, more cost-effective replacement of various components throughout an aircraft. Distributed manufacturing allows Airbus to produce parts where and when they’re needed, helping reduce aircraft downtime, minimize inventory storage, and avoid costly supply chain delays.

“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.”

Stratasys has decades of experience meeting the aerospace industry’s most demanding standards, with a portfolio of high-performance materials and additive manufacturing platforms trusted by major OEMs and suppliers globally. Its solutions are proven to deliver certified, repeatable parts for production and maintenance, repair, and overhaul (MRO) applications, helping aerospace leaders keep fleets flying while lowering operational costs.