The Future of Travel: How 3D Printing in the US, UAE, Japan and More is Transforming Aviation, Space, and Infrastructure

Published on December 27, 2025

By: Paramita Sarkar

3D printing, also known as Additive Manufacturing (AM), is emerging as a game-changing technology in the travel and transportation sectors. From cutting-edge developments in aerospace to transforming hospitality infrastructure, 3D printing is reshaping the way travel is experienced and delivered across the world. Countries like the United States, China, the UAE, Russia, and Europe are spearheading this transformation, with groundbreaking projects that promise not only to improve efficiency but also to make travel more sustainable and cost-effective.

What Is the Impact of 3D Printing on the Travel Industry?

3D printing is revolutionizing multiple aspects of the travel industry, particularly in aerospace, supply chain management, space travel, hospitality, and sustainability. By shifting away from traditional manufacturing methods, which rely on subtractive processes and physical inventories, 3D printing offers a new frontier in efficiency, cost reduction, and environmental sustainability.

Where is 3D Printing Making the Most Impact?

Aerospace: Enhancing Efficiency and Reducing Costs

The aviation industry is one of the main beneficiaries of 3D printing. According to reports from NASA and the Federal Aviation Administration (FAA), 3D printing in aviation has focused on lightweighting and part consolidation—two processes aimed at improving fuel efficiency and structural integrity. With the ability to create lattice structures that were once impossible with traditional manufacturing, the weight of components can be reduced by 40% to 60%, saving airlines substantial fuel costs.

For instance, a single pound of weight removed from an aircraft saves approximately $14,000 in fuel costs over the vehicle’s lifespan, according to the U.S. Department of Energy (DOE). Additionally, NASA has tested 3D-printed rocket engine parts, and commercial engines like the GE9X engine include over 300 3D-printed components, including fuel nozzles that are five times more durable than previous designs. These technological advancements in 3D printing also extend to the FAA’s certification of critical 3D-printed parts, ensuring that they meet rigorous safety standards similar to traditionally manufactured components.

Space Travel: Printing for the Moon, Mars, and Beyond

The space industry has also embraced 3D printing as a necessary tool for long-distance travel. The NASA Artemis Program and European Space Agency (ESA) are exploring 3D printing to build vital infrastructure in space, reducing reliance on expensive transportation from Earth. Notably, NASA’s Project Olympus, under the ICON project, is working to 3D print structures using lunar regolith (moon dust) as raw material to construct landing pads and habitats. This approach would allow lunar infrastructure to be built without the exorbitant costs of transporting materials, which currently stands at over $1.2 million per kilogram.

Moreover, NASA’s “3D Printing in Zero-G” experiment aboard the International Space Station (ISS) has demonstrated that 3D-printed parts maintain the same structural integrity in microgravity as they would on Earth. This development could prove crucial for long-term human habitation on the Moon or Mars, where in-situ resource utilization (ISRU) is essential for sustainability.

Supply Chain: Digital Warehouses and On-Demand Manufacturing

The rise of 3D printing is also shaking up the traditional supply chain model in travel, with the transition from physical inventories to a “digital inventory” approach. The International Transport Forum (ITF) has noted that 3D printing is helping airlines and rail operators eliminate the need for storing large volumes of spare parts.

For example, airlines can now produce parts on-demand to avoid the costly Aircraft on Ground (AOG) scenarios, where a minor component failure can cost airlines over $10,000 per hour in lost revenue. Rail operators such as Deutsche Bahn and SNCF are using additive manufacturing to produce obsolete parts for trains that are over 30 years old, bypassing the high costs of maintaining molds and physical spare parts.

Hospitality: Building the Future with 3D-Printed Structures

In the hospitality sector, Dubai has announced an ambitious plan to 3D-print 25% of all new buildings by 2030, including hotels and tourism offices. This initiative is a part of the Dubai 3D Printing Strategy, which aims to reduce material waste by up to 60% and labor costs by 50% to 80%. The benefits are clear: 3D construction printing allows for the rapid deployment of eco-friendly resorts in remote destinations, which might otherwise be too expensive or environmentally damaging to build with traditional methods.

Furthermore, UN-Habitat has noted that 3D printing enables the creation of sustainable structures with significantly reduced environmental impact, making it a perfect solution for the growing demand for eco-tourism and remote accommodations.

How Is 3D Printing Contributing to Sustainability in Travel?

One of the most significant advantages of 3D printing in travel is its positive impact on the environment. The “Buy-to-Fly” ratio in traditional aerospace manufacturing—the weight of raw material compared to the weight of the final part—can be as high as 20:1. 3D printing drastically reduces this ratio, bringing it closer to 1.5:1, minimizing the carbon footprint associated with manufacturing travel vehicles.

Additionally, the U.S. Navy has experimented with plastic waste on ships, grinding it down and re-printing it into functional tools, showcasing a potential circular economy model for cruise ships and other travel-related infrastructure.

What’s Next?

As the technology continues to advance, 3D printing is set to play an even larger role in revolutionizing the travel industry. From aviation to space travel and sustainable infrastructure, 3D printing is providing solutions that are both cost-effective and environmentally responsible. The US, Europe, China, Russia, and the UAE are leading the charge, and as the technology becomes more mainstream, the potential applications for 3D printing in travel are virtually limitless.