Discover The Future Of Air Travel With 3D Printed Parts In Airbus Aircraft

Published on December 10, 2025

Airbus and StrataSys offer the aerospace industry the very latest 3D printing technologies that have changed the industry’s approach to aircraft production and maintenance. They have started to produce over 25,000 certified parts, which have changed the production history and maintenance approach for most of Airbus’ aircraft, the A320, the A350, and the A400M. The collaboration has bent history at the crossroads of mass production, aircraft maintenance, and technological advancement.

The incorporation of StrataSys’s 3D printing technology into the Airbus production process has changed the history of aerospace production, breaking down technological production barriers and adding unmatched efficiencies to the process. The industry positioned Airbus to opt for polymer additive manufacturing and production of flight certification-compliant military aircraft like the A400. The parts manufactured increase aircraft efficiencies and shift the aerospace industry to lower carbon emissions and increased sustainability.

The Role of 3D Printing in Aerospace

From manufacturing spares like crew seat parts to critical flight-ready parts with the ULTEM™ 9085 3D printing technology, StrataSys has changed the manufacturing process for Airbus. With ULTEM™ 9085, Airbus has been able to produce parts that meet all requirements for the aerospace industry.

Parts created by Stratasys using certified ULTEM™ 9085 filament have benefits that traditional methods of manufacturing don’t have. Studies show that because of using 3D-printed parts on the A350, some components have seen a 43% reduction in weight. This reduction in weight helps the aircraft become more fuel-efficient, and in turn, helps Airbus accomplish its mission of being carbon neutral by 2050.

One of the most impressive results of this partnership has also been an 85% reduction in lead time and, as a result, a dramatic reduction in the cost of time of production time and cost of production time spent on production. With the removal of the Minimum Order Quantity (MOQ) requirement, Airbus has more freedom to produce parts on demand, and, as a result, does not experience the traditional delays associated with sourcing and producing spare parts.

These are the primary benefits of distributed manufacturing

Stratasys and Airbus worked together to manufacture products differently by preparing to build components at the time and place they will be needed. This form of manufacturing decreases the time airlines spend on runway maintenance and allows Airbus to store and access a costly inventory. The on-demand, on-site printing of aircraft components reduces the risk that global airlines have faced for a long time.

This aircraft’s distributed model ensures there will be no disruptions due to global supply chain issues. This is very beneficial for aircraft maintenance and repair in remote locations where conventional supply chains can be unreliable.

Global Services Certified Parts

Airbus began its journey into 3D printing tech across the various models, including the A320, A350, and A400M, and it continues to diversify to this day. Currently, over 200,000 certified Stratasys parts are active across the globe. Stratasys technology flagship services innovation to the aerospace industry as it meets the first and highest quality certified parts requirements from the FAA and other aviation authorities.

Although testing 3D printed parts and processes to meet the aviation industry safety and reliability requirements is complex and rigorous, it is this technology from Stratasys and other qualified certified vendors that gives the reliability and consistency needed to serve aviation.

Effects on the Aerospace Sector

The part of this partnership that has most of the aerospace sector talking, however, is the certification of 3D printed parts for actual use in aviation, achieving another benchmark in the industry. This collaboration is anticipated to be a paradigm shift, with industry experts indicating that this is the point where additive manufacturing is no longer exclusively used for prototyping, but rather, is fully integrated into the mainstream for large-scale production. As the industry continues to seek more lightweight, faster, and more resilient supply chains, the technology to meet 3D printing is ready to supply these needs.

With over 3 decades of experience serving the aerospace sector, Stratasys has proven to be a technology partner for many of the regional and global aerospace leaders. Keeping them with high operational efficiencies, cost savings, and fleet increases. Keeping global leaders’ fleets flying to top performance adds to the companies’ list of high-performing assets in their portfolio of trusted high-performance materials and manufacturing platforms.

Sustainability and the Road Ahead

With the anticipated integration of additive manufacturing in aerospace production technologies, the anticipated waste and energy use during production of parts will make improvements of traditional aerospace production methods seem wasteful by comparison. With the increasing integration of 3D printing by Stratasys and Airbus, the anticipated environmental benefits will be brought to the forefront of modern production methods in the Aerospace industry.

And most importantly, 3D printing technology is helping to achieve sustainability goals in the aerospace industry and to help companies like Airbus meet the challenges posed by the problems. Reducing the carbon footprint is a matter of printing lighter parts to help achieve fuel efficiency, and being able to produce 3D-printed parts is a matter of fuel efficiency.

Conclusion: The Revolution in Aviation Production

The mutual collaboration of Stratasys and Airbus is the beginning of a new period in the production of aerospace. Additive 3D printing technology is no longer a novelty, but is essential for aircraft production and maintenance. Airbus is the first in the 21st century to embrace the notions of distributed production and certified additive manufacturing, and is the first in the industry to set the aviation rules.

Airbus and Stratasys are not only changing the skies by changing the method of manufacturing aircraft, but are also paving the way for a new technology in aviation: 3D printing. The printing of aircraft components in three-dimensional technology saves and provides sustainability and efficiency across the aviation industry. The 3D printing technology has the potential to change the world and the aerospace industry.