The 3D printing promise of weight optimization is not about parts, it’s about systems

A key lesson learned talking with aerospace 3D printing companies at PAS 2019, that can be applied to all industrial segments

The Paris Air Show was a huge success for the largest aerospace players and for many innovative aerospace 3D printing companies. The aviation and space industries are rocketing toward booming growth with no slow down anywhere on the horizon. While additive manufacturing is still just a tiny – to use a euphemism – segment of aerospace manufacturing, all leading companies in aerospace are very much invested in developing it. The reason may be found in one of the largest deals ever closed during the show: the $55 billion in orders that CFM – a joint venture between GE and Safran – received for its LEAP engine. The LEAP engine is super efficient and is enabling a new generation of single-aisle jets – such as the Airbus321neo flown by French operator Le Compagnie in its new all-business flights – to make trips across the Atlantic on a single tank of fuel.

Last April, for instance, a LEAP-engine-powered Airbus A321neo LR loaded with 162 dummy passengers and 16 crew completed a test flight from Airbus headquarters in Toulouse, France, to the Seychelles islands in the Indian Ocean that lasted 11 hours and covered 5,466 miles. It was the longest distance flight in the certification process of the A321neo. At the Paris Air Show Airbus formally unveiled a new long-range A321neo, officially designated the A321XLR, which will become available from 2023. The twinjet will have a maximum take-off weight of 101t and a range of 4,700nm compared with the 4,000nm of the current 97t long-range A321LR variant. GE and most operators expect that these efficient single-aisle aircraft will make up the bulk of order for the foreseeable future.

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