Satair 3D-prints first flightworthy spare part for Airbus A320ceo

Satair additively manufactured a titanium wingtip fence for an A320ceo aircraft to replace the original cast fence. Airbus

Airbus subsidiary Satair has shipped a U.S customer what it says is the first certified, flightworthy spare part 3D-printed from metal. The A320ceo-specific cast wingtip fence is no longer procurable from the original supplier, which prompted Satair to suggest additively manufacturing it.

The spare-parts supplier also studied other conventional options, such as redesigning the part for machining, but the idea was ruled out because the resulting cost was deemed too high and the lead time too long.

Satair Head of Additive Manufacturing Felix Hammerschmidt said the part was handed over to the RapidSpares design office at Airbus and, “using a new certification process, they were able to recertify the former cast part within five weeks and adapt it to titanium, which is a qualified airworthy additive manufacturing material.”

Four wingtip fences, which comprise a full shipset for one aircraft, are printed simultaneously. The job takes 26 hours. Different postprocessing steps are required to make the parts flightworthy. The shipset was delivered earlier this year.

Compared to conventional methods, 3D printing reduced total nonrecurring costs by 45% and shortened the lead time, reports the aero-parts manufacturer.

The company’s CEO, Bart Reijnen, said, “With more than 7,000 A320ceo Family aircraft in service worldwide, the demand for this specific additively manufactured part is likely to increase. And with this supply chain now in place, we will be able to produce these parts with a shorter lead time.”

Four other customers have asked Satair to print wingtip fences.

More than 7,000 A320ceo aircraft are in service, which likely will result in additional wingtip fences being 3D-printed.