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
Baxter Aerospace Invests $19.55M in Utah Manufacturing Facility
Baxter Aerospace expands into Washington County, Utah with a $19.55M facility to scale UAS and satellite comms production.
Baxter Aerospace will invest $19.55 million to lease and equip a new manufacturing facility in Washington County, Utah, transitioning its unmanned aircraft and communications systems from prototype development into full-scale production.
The expansion, announced in an October 8, 2026, press release by the Utah Governor’s Office of Economic Development (GOED), is projected to create 90 high-paying jobs over the next five years while strengthening the state’s aerospace and defense industrial base.
Transitioning to full-scale production
The new facility in Washington City will feature high-capacity infrastructure, specialized testing spaces, and security systems. This site is designed to support mission-critical work across aerospace, defense, satellite communications, autonomous aircraft, and public safety.
Baxter Aerospace CEO Jeff Baxter stated that expanding in southern Utah allows the company to increase manufacturing capacity and support growing customer needs. He noted the company is prepared to help shape the region’s aerospace future.
The project is backed by a Rural Economic Development Tax Increment Financing (REDTIF) post-performance tax credit approved by the GOED. Under the agreement, Baxter Aerospace can earn a rebate of up to 30% on new state revenues generated over the five-year term, capped at $456,939.
State officials project the expansion will generate $20,758,160 in new state wages and $1,523,131 in new state tax revenue during that period. GOED Commissioner Jefferson Moss noted that the investment signals Utah’s economic future is fueled by frontier innovation. Washington County Commissioner Adam Snow added that the expansion connects local talent with emerging aerospace opportunities.
Scaling the BA-1 Dragonfly and defense portfolio
The manufacturing expansion follows a period of steady growth for the St. George-based defense and aerospace innovator. Brothers Jeff and Michael Baxter founded the company in 2015 following a severe Oregon wildfire, focusing their initial efforts on real-time sensing, resilient communications, and autonomous systems for emergency response and defense applications.
The company’s flagship aerospace product is the BA-1 Dragonfly. The Dragonfly is a Group 3 vertical takeoff and landing (eVTOL) unmanned aircraft system designed for intelligence, surveillance, and reconnaissance (ISR) missions, featuring over 12 hours of endurance.
Alongside the BA-1 Dragonfly, Baxter Aerospace produces deployable broadband satellite communications kits that utilize low Earth orbit (LEO) networks. The company also manufactures precision components for the fusion and nuclear energy sectors.
To support the scaling of these product lines, Baxter Aerospace secured a $6 million Series A funding round in July 2025. The capital was raised from the Department of Defense (DoD) Accelerator fund, managed by Accuidity Capital Management, specifically to accelerate production of the Dragonfly system and the deployable communications kits. The new Washington County facility represents the physical infrastructure required to execute that production scale-up between late 2026 and 2031.
Photo Credit: Utah Governor’s Office of Economic Development
MRO & Manufacturing
IAI 777-300ERSF P2F Conversions Launch in North America
The first Boeing 777-300ER for P2F conversion in North America arrives at Ascent Aviation Services in Marana, Arizona.
The first Boeing 777-300ER slated for passenger-to-freighter (P2F) conversion in North America arrived at Ascent Aviation Services in Marana, Arizona, on October 22, 2026. The induction marks the regional launch of the Israel Aerospace Industries (IAI) modification program for the widebody twinjet.
The arrival of the World Star Aviation aircraft initiates operations at a newly expanded site designed to increase global capacity for the Boeing 777-300ERSF program, according to a joint press release issued by the companies.
Expanding global conversion capacity
Ascent Aviation Services, an independent aircraft aftermarket service provider and Federal Aviation Administration (FAA) Class IV Part 145 certified repair station, will operate two parallel conversion lines at its Pinal Air Park campus. To accommodate the Boeing 777-300ERSF program, the company invested $70 million to construct two 90,000-square-foot widebody hangars. Ascent broke ground on the facilities on March 29, 2024, effectively tripling the site’s hangar capacity.
“The launch of Boeing 777-300ERSF conversions in North America marks an important milestone for IAI’s global conversion program,” Yaacov Berkovitz, executive vice president and general manager of IAI Aviation Group, stated in the release. “Together with Ascent Aviation Services, we are expanding production capacity and bringing our conversion capabilities closer to customers in the region.”
Ascent Aviation Services chief executive officer David Querio noted that the induction represents the beginning of a long-term partnership with IAI, with multiple Boeing 777-300ERSF conversions planned for the Marana site.
“Our vision is to shape the future of aviation by turning engineering innovation into lasting value for our customers,” IAI president and chief executive officer Guy Bar Lev added. “Passenger-to-freighter conversions are a key part of that vision, extending the productive life of aircraft and helping airlines adapt to changing market needs.”
World Star Aviation’s fleet strategy
The inaugural aircraft belongs to World Star Aviation, a full-service aircraft and engine lessor headquartered in London. The company specializes in mid-to-late life assets and manages a portfolio of approximately 150 aircraft and engines. This includes 60 narrowbody and widebody freighters currently on lease to cargo operators globally.
World Star Aviation partner Yoyo Allalouf cited the strength of the IAI program during a critical period for widebody passenger-to-freighter production as the primary driver for their selection.
“IAI’s dominance in the widebody P2F space, demonstrated by its Boeing 747 and 767 programs, together with our long-standing relationship, underpinned our decision to choose IAI for the 777-300ERSF,” added Garreth Slevin, partner at World Star Aviation.
The rise of the “Big Twin” freighter
The Boeing 777-300ERSF program, marketed as “The Big Twin,” launched on October 22, 2019, as a joint venture between IAI and GECAS, which was subsequently acquired by AerCap. It remains the only certified P2F conversion program for the Boeing 777-300ER.
The converted freighter offers 25 percent more cargo volume than a production Boeing 777-200LRF and 15 percent more volume than a Boeing 747-400BCF. This capacity positions the aircraft as a direct replacement for aging Boeing 747-400 and McDonnell Douglas MD-11 freighter fleets.
IAI brings over 50 years of experience to the program, having delivered more than 350 converted cargo aircraft across Boeing 747, 767, 737, and Airbus A330 platforms. The company currently holds a dominant market share in medium-size freighter conversions, particularly with the Boeing 767.
The 777-300ERSF recently transitioned from certification into commercial service. In August 2026, Challenge Group took delivery of its second 777-300ERSF, which marked the fifth redelivery of the type across the industry for the year.
AirPro News analysis
We view the activation of the Marana conversion lines as a critical step in maturing the Boeing 777-300ERSF program. By establishing a North American footprint, IAI mitigates geographic bottlenecks and provides operators with a domestic option for heavy modifications. The $70 million infrastructure investment by Ascent Aviation Services indicates strong long-term confidence in the widebody conversion market, even as the air cargo sector normalizes following pandemic-era peaks. As legacy quad-engine and tri-engine freighters approach mandatory retirement or become economically unviable, the availability of parallel conversion lines in the United States ensures IAI can capture a significant share of the impending widebody replacement cycle.
Photo Credit: IAI
MRO & Manufacturing
Cirrus Aircraft Breaks Ground on $8M Engine Run-Up Center
Cirrus Aircraft begins construction on a 15,000-sq-ft Engine Run-Up Center in Duluth, MN, set to open summer 2027.
Cirrus Aircraft has commenced construction on an $8 million, 15,000-square-foot Engine Run-Up Center in Duluth, Minnesota, moving critical engine testing and fuel calibration processes into a year-round, climate-controlled environment.
The new facility, detailed in a company press release on October 23, 2026, is designed to support the certification process for the SR Series, Vision Jet, and TRAC10 aircraft while reducing noise at the surrounding airport.
Centralizing certification operations
The Engine Run-Up Center will consolidate several final-phase manufacturing steps into a single enclosed building. The facility will house two calibration stalls dedicated to engine setup and testing, utilizing an 8-foot exhaust collector to ventilate the spaces. A separate climate-controlled control room will allow technicians to conduct data analysis during the testing phase.
In addition to the testing stalls, the building will include two stalls specifically engineered for fueling and defueling aircraft. These areas incorporate specialized fire protection systems and are designed to meet requirements for handling flammable fluids.
Cirrus Chief Executive Officer Zean Nielsen stated that engine run-ups and fuel system calibration are essential processes across aircraft manufacturing. He noted that the modern facility will allow the company to streamline these critical operations, improve efficiency, and provide team members with a dedicated environment to perform the work.
Expanding the Duluth manufacturing footprint
The new testing center adds to an existing corporate footprint that exceeds 1.3 million square feet. The majority of this infrastructure is located in Duluth, which serves as the primary production hub for the manufacturer.
Founded in 1984 and now publicly traded on the Hong Kong Stock Exchange, Cirrus has manufactured more than 12,000 SR Series piston aircraft and Vision Jets to date. The groundbreaking follows closely on a major program milestone for the company. On October 21, 2026, Cirrus celebrated the 10-year anniversary of Federal Aviation Administration (FAA) type certification for the Vision Jet, the first single-engine personal jet to reach the market.
Patrick Waddick, President of Innovation & Operations at Cirrus, highlighted the scale of the company’s historical output in Duluth. He noted that the new facility expands a footprint where the company has produced its entire fleet of over 12,000 aircraft, adding that the manufacturer has spent decades challenging conventions through innovations that transform personal aviation.
Project timeline and operational impact
Construction on the Engine Run-Up Center is underway, with the facility expected to open and become fully operational by the summer of 2027. By moving engine testing indoors, the company anticipates a reduction in noise levels for the surrounding airport environment, a common challenge for manufacturers conducting high-power engine runs on open ramps.
The $8 million investment reflects broader efforts by the airframer to scale production capabilities in response to market requirements. Nielsen indicated that as the company continues to grow, investments in manufacturing infrastructure position Cirrus to meet customer demand while maintaining high standards of quality and safety.
Photo Credit: Cirrus Aircraft
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