MRO & Manufacturing
Airbus Starts Serial Production of Large Titanium 3D-Printed A350 Parts
Airbus initiates serial integration of large titanium 3D-printed parts for the A350 using w-DED technology in partnership with Norsk Titanium.

This article is based on an official press release from Airbus and additional industry data regarding Norsk Titanium.
Airbus Initiates Serial Production of Large Titanium 3D-Printed Parts for A350
As of January 2026, Airbus has officially commenced the serial integration of large-scale, 3D-printed titanium components into the A350 program. According to an official company statement, this milestone focuses on the Cargo Door Surround area of the Commercial-Aircraft, marking a decisive shift from traditional Manufacturing methods to advanced Wire-Directed Energy Deposition (w-DED) technology.
This development represents a significant evolution in aerospace manufacturing. While 3D printing (additive manufacturing) has been used previously for smaller brackets and non-structural cabin parts, the move to w-DED allows for the production of large, high-load-bearing structural components. Airbus indicates that this transition is driven by the need to reduce raw material waste, shorten production lead times, and prepare for the high-rate demands of future aircraft programs.
The Shift to Wire-Directed Energy Deposition (w-DED)
Historically, the aerospace sector has relied heavily on “Powder Bed Fusion” for additive manufacturing. While precise, this method is constrained by the size of the printer’s bed, typically under two feet, and relatively slow production speeds measured in grams per hour. In its recent announcement, Airbus detailed its adoption of w-DED to overcome these limitations.
Breaking Size and Speed Barriers
The w-DED process utilizes a robotic arm to feed titanium wire into a laser or plasma beam, melting the material layer-by-layer to build a part. According to technical details released by Airbus, this method offers two primary advantages over powder-based systems:
- Scale: The robotic nature of w-DED allows for the creation of components up to 7 meters (23 feet) in length, enabling the production of large structural ribs and frames.
- Speed: Deposition rates have increased from grams per hour to several kilograms per hour, making the technology viable for industrial-scale serial production rather than just prototyping.
The parts currently being installed on the A350 Cargo Door Surround are produced as “near-net shapes.” This means the component is printed to a rough outline of the final specification and then machined to exact tolerances. This hybrid approach combines the speed of additive manufacturing with the precision of traditional machining.
Sustainability and Efficiency Gains
A primary driver for this technological shift is the drastic reduction in material waste, measured in the industry by the “Buy-to-Fly” ratio. This ratio compares the weight of the raw material purchased to the weight of the final finished part.
According to industry data and Airbus’s manufacturing analysis:
- Traditional Forging: Often requires a Buy-to-Fly ratio of 10:1 to 20:1. This means for every 1 kilogram of finished part, 10 to 20 kilograms of raw titanium must be purchased, with 80-95% of that material machined away as scrap.
- w-DED Printing: Achieves a ratio closer to 2:1. Only about 2 kilograms of wire are needed for a 1-kilogram part, resulting in significantly less waste.
By reducing the amount of titanium required, Airbus aims to lower both environmental impact and production costs. Furthermore, the digital nature of the process reduces lead times from months to weeks, as it eliminates the need to create physical molds or dies associated with forging.
Strategic Partnerships and Future Programs
The successful integration of these parts is supported by a partnership with Norsk Titanium. Following a Master Supply Agreement signed in April 2024, Norsk Titanium has utilized its proprietary Rapid Plasma Deposition (RPD) technology to supply these structural components. This collaboration has been instrumental in moving the technology from a testing phase to serial mass production.
Enabling the ZEROe and Next-Gen Single-Aisle
Airbus has stated that the A350 application serves as a “stepping stone” for more ambitious future projects. The scalability of w-DED is considered critical for two upcoming challenges:
- High-Rate Production: The successor to the A320 family, expected in the late 2030s, will require production rates that traditional forging supply chains may struggle to support. w-DED allows for on-demand printing of large parts, potentially alleviating supply bottlenecks.
- Hydrogen Aircraft (ZEROe): Future Hydrogen-powered aircraft will require complex cryogenic fuel tanks. w-DED is uniquely suited to print these large, hermetically sealed structures as single pieces, reducing joints and minimizing the risk of leaks.
AirPro News Analysis
The adoption of w-DED for the A350 Cargo Door Surround signals that Airbus is moving aggressively to close the gap with competitors in the additive manufacturing space. Boeing has utilized Norsk Titanium’s RPD parts on the 787 Dreamliner since approximately 2017 to reduce costs. However, Airbus’s application appears to target larger and more complex structural areas, suggesting a strategy of “catch-up and scale-up.”
Furthermore, this move validates the broader industry trend toward “Near-Net Shape” manufacturing. As geopolitical and supply chain instabilities continue to affect the availability of raw titanium, technologies that reduce material consumption by up to 90% are no longer just “green” initiatives, they are strategic necessities for maintaining production stability.
Frequently Asked Questions
What is w-DED?
Wire-Directed Energy Deposition (w-DED) is a 3D printing technique that uses a laser or plasma beam to melt metal wire as it is deposited by a robotic arm. It is faster and capable of building larger parts than traditional powder-bed fusion.
Which aircraft are using these parts?
As of January 2026, the parts are being serially integrated into the Airbus A350, specifically in the Cargo Door Surround area.
Who is the supplier for these parts?
The parts are produced in partnership with Norsk Titanium, utilizing their Rapid Plasma Deposition (RPD) technology.
Sources: Airbus, Norsk Titanium
Photo Credit: Airbus
MRO & Manufacturing
Lion Group Opens Batam Aero Engine MRO Facility in Indonesia
Lion Group launched Batam Aero Engine on Aug 19, 2026, offering engine and APU MRO services to serve Southeast Asian operators.

Lion Group has officially commenced operations at its new Batam Aero Engine maintenance, repair, and overhaul (MRO) facility in Indonesia, aiming to capture a larger share of the Asian engine maintenance market and reduce domestic reliance on foreign service providers.
The facility, which opened on August 19, 2026, provides both on-wing and off-wing maintenance for jet engines, turboprop engines, and Auxiliary Power Units (APUs). The Launch was detailed in a press release issued by Lion Group on August 21, 2026, highlighting the company’s push to localize critical aviation supply chains.
Technical capabilities and infrastructure
Batam Aero Engine enters the market with specialized diagnostic and repair capabilities designed to service a variety of powerplants. According to the Lion Group press release, the facility is equipped to perform complex procedures including Low Pressure Turbine (LPT) module replacements.
The maintenance center also features advanced borescope inspection equipment. Certified personnel will utilize IPLEX NX, IPLEX GX/GT, and Mentor Flex systems to conduct internal engine diagnostics. These capabilities allow technicians to assess engine health and identify potential defects without requiring full engine teardowns, thereby reducing maintenance turnaround times for operators.
Strategic expansion in the Asian MRO market
The inauguration event in Batam drew key figures from both the company and Indonesian regulatory bodies, including Lion Group Founder Rusdi Kirana and Batam Mayor Dr. Amsakar Achmad. The strategic placement of the facility in Batam leverages existing industrial infrastructure and proximity to regional trade routes to attract maintenance contracts from across Southeast Asia-Pacific.
Lion Group President Director Captain Daniel Putut Kuncoro Adi emphasized the dual focus of the new enterprise.
“We hope this facility can serve domestic needs as well as friendly countries and further strengthen Indonesia’s aviation industry,” Adi stated, according to reporting by Aviation Business News.
Indonesian regulators also view the facility as a step toward greater self-sufficiency in the aviation sector. Sokhib Al Rokhman, Director of Airworthiness and Aircraft Operations at Indonesia’s Directorate General of Civil Aviation (DGCA), highlighted the broader national strategy during the launch.
“We want to strengthen aviation independence by making Batam Aero Engine an MRO hub that is efficient, responsive, and competitive in the Asian market,” Rokhman said, as reported by ePlaneAI.
AirPro News analysis
The establishment of Batam Aero Engine represents a calculated vertical integration Strategy by Lion Group. By bringing engine and APU maintenance in-house, the operator can better control maintenance costs and mitigate Supply-Chain bottlenecks that have constrained the global MRO sector in recent years. Furthermore, positioning the facility in Batam allows Indonesia to compete directly with established MRO hubs in neighboring Singapore and Malaysia. If the facility can secure third-party contracts as intended, it will mark a significant maturation of Indonesia’s domestic aviation technical capabilities and workforce.
Sources: Lion Air Public Relations
Photo Credit: Batam Aero Engine
MRO & Manufacturing
2026 GA Parts Survey: Supply Chain Pressures on Aging Fleet
TBX survey finds 66% of GA maintenance pros expect parts availability to worsen as the piston fleet averages 53 years old.

General aviation maintenance professionals are spending more time hunting for parts and technical data than managing costs, as supply chain friction threatens the operational viability of an aging piston aircraft fleet.
In a press release issued on August 23, 2026, TBX, operating as Airworthy.com, published the findings of its 2026 General Aviation Parts Survey. The accompanying summary report, titled “The Great Parts Squeeze,” details the mounting pressures on maintenance shops tasked with servicing a certified general aviation (GA) piston fleet that now averages 53 years of age.
Supply chain friction and industry sentiment
The survey data indicates widespread pessimism regarding the near-term outlook for component availability. According to the report, 66% of surveyed industry professionals expect the aviation parts supply environment to worsen in the near future. Dissatisfaction is prevalent across multiple metrics, with 72% of respondents reporting frustration with parts pricing and 59% expressing dissatisfaction with current lead times.
Despite the high concern over pricing, the report highlights that the sheer time required to source components and access Illustrated Parts Catalogs (IPCs) has become the primary operational bottleneck for maintenance providers.
“Maintenance shops are spending too much time searching for parts, finding part numbers, waiting on backorders, and sourcing alternatives,” said Jon McLaughlin, CEO of TBX.
McLaughlin added that this administrative burden includes the time spent explaining limited options, or the complete lack thereof, to customers waiting for their aircraft to return to service.
Strategies for an aging piston fleet
With the average certified GA piston aircraft now over half a century old, the industry faces compounding challenges in keeping legacy airframes airworthy. The TBX report suggests that maintaining this fleet will require broader acceptance and availability of alternative components, including Parts Manufacturer Approval (PMA) items and serviceable used parts, alongside traditional Original Equipment Manufacturer (OEMs) supplies.
“As the GA fleet continues to age, improving parts availability, expanding access to technical data, and giving maintainers more options will be critical to keeping these aircraft flying,” McLaughlin stated in the release.
The company intends for the survey data to serve as a baseline for manufacturers and suppliers to address these bottlenecks. McLaughlin noted that the friction points identified by maintenance professionals require a coordinated response, stating that the issue cannot be solved by any single segment of the industry alone.
AirPro News analysis
The findings in the TBX report quantify a reality we hear frequently from general aviation maintenance providers. As the legacy piston fleet ages past the 50-year mark, the original supply-chains that supported these aircraft have often consolidated, pivoted to turbine markets, or ceased operations entirely. The high dissatisfaction with lead times points to a structural gap in the market. While PMA manufacturers have stepped in to produce high-demand replacement parts, the long tail of low-volume, specialized components remains a significant vulnerability for GA operators. If supply chain friction continues to outpace solutions, we may see an increase in aircraft grounded not for lack of funds, but for lack of basic hardware and approved technical data.
Sources: TBX via PR Newswire
Photo Credit: Stock Image
MRO & Manufacturing
Pem-Air Selects Ramco Aviation Software for Engine MRO Growth
Pem-Air adopts Ramco Aviation Software to manage GE90, Trent 700, and CFM LEAP engine MRO operations with AI-driven workflows.

Florida-based engine maintenance provider Pem-Air has selected Ramco Aviation Software to manage its expanding maintenance, repair, and overhaul (MRO) operations. The transition to the digital platform, announced on August 19, 2026, is designed to support the company’s growth into larger and next-generation engine platforms, including the GE90, Trent 700, and CFM LEAP.
In a press release issued by Ramco Systems, the software provider detailed that the integration will connect every stage of a shop visit into a single system. The move aims to reduce turnaround times and facilitate paperless operations for Pem-Air, which holds certifications from both the Federal Aviation Administration (FAA) and the European Union Aviation Safety Agency (EASA).
AI integration and technical workflows
The Ramco platform incorporates artificial intelligence capabilities intended to streamline technical workflows on the shop floor. A key feature is the Service Bulletin Agent, which extracts data from unstructured technical documents, such as Service Bulletins (SB) and Airworthiness Directives (AD), to automatically generate Engineering Orders (EO).
The software also utilizes generative AI assistants to review reports and monitor real-time operational status. To assist technicians, the system recommends corrective actions for maintenance discrepancies based on historical resolution data. Ramco states this feature is designed to help standardize decision-making and resolve mechanical issues more efficiently.
Supporting engine portfolio expansion
Pem-Air has been actively growing its engine portfolio to include larger widebody powerplants and next-generation narrowbody engines. The adoption of Ramco’s Software is positioned as a technological foundation to manage the increased complexity associated with these newer platforms.
“As we scale our engine MRO capabilities, we needed a platform that could keep pace with that growth. Ramco stood out in our evaluation for its end-to-end lifecycle coverage, deep engine MRO expertise, and strong credibility in the U.S. market. We built our name on quality and reliability, and we are confident that Ramco Aviation Software will enable us to continue exceeding what our customers expect from every repair.”
The quote was provided by Virgil Pizer, Chief Executive Officer of Pem-Air. Manoj Kumar Singh, Chief Customer Officer for Aviation, Aerospace & Defense at Ramco Systems, noted that the software was built to meet evolving segment demands, with AI positioned at the center of efforts to reduce customer turnaround times.
AirPro News analysis
We observe that the transition to integrated, AI-supported software platforms is becoming a baseline requirement for independent MRO providers scaling up to handle next-generation engines like the CFM LEAP. As engine complexity increases and technical documentation grows more voluminous, the ability to automate the translation of Airworthiness Directives into actionable Engineering Orders provides a distinct competitive advantage. For facilities like Pem-Air, reducing administrative overhead during shop visits is critical to maintaining throughput and minimizing turnaround times in a highly constrained global engine maintenance market.
Sources: Ramco Systems
Photo Credit: Ramco Systems
-
UAV & Drones6 days agoDufour Aerospace Aero-200 eVTOL Targets 2027 Serial Production
-
Technology & Innovation4 days agoSkyband Systems M100 LRU Validates GNSS Jamming Protection
-
MRO & Manufacturing3 days agoBoeing SPEEA Engineers Reject Contract, Authorize Strike
-
Route Development7 days agoMWAA Approves $15.5B Budget for Washington Dulles Overhaul
-
Military Technology3 days agoSaab Unveils A3-001 Supersonic Stealth Drone Concept
