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
JCB Aero Gains Part 145 Approval for Boeing 737 Family
JCB Aero receives Part 145 approval for Boeing 737 base and line maintenance, expanding beyond its Airbus MRO operations in Auch, France.
JCB Aero has secured Part 145 maintenance approval to perform base and line maintenance on the Boeing 737 aircraft family, expanding the French facility’s capabilities beyond its established Airbus operations.
The approval, received in August 2026 and announced by the company on September 3, 2026, covers the Boeing 737-600, Boeing 737-700, Boeing 737-800, and Boeing 737-900 variants. Located in Auch, near Toulouse, the subsidiary of the AMAC Aerospace Group initially launched its MRO operations in October 2024 with a focus on Airbus airframes.
Expanding MRO capabilities in Auch
The addition of Boeing 737 maintenance authorization allows JCB Aero to capture a broader segment of the narrowbody market. The company stated it has already begun issuing quotations for Boeing operators and expects to induct the first 737 airframes into its hangar in the coming months.
This expansion follows a period of high utilization for the Auch facility. Earlier in 2026, AMAC Aerospace reported full hangar capacity at the site, driven by maintenance and modification projects on Airbus Corporate Jets, specifically the ACJ318 and ACJ319 platforms.
Management perspective on the Boeing approval
The certification aligns with recent leadership transitions at the company, including the March 2026 appointment of Sébastien Kubler as Chief Operating Officer. Kubler previously served as the technical director of production and engineering for the firm.
In a statement regarding the new certification, Kubler highlighted the strategic value of the dual-manufacturer capability:
“Receiving this Boeing approval marks an important milestone in the development of JCB Aero’s MRO activities. Adding the Boeing 737 family to our existing Airbus capabilities enables us to serve a wider range of customers and further strengthens our position as a flexible and responsive MRO partner. This achievement is also a great recognition of the commitment and expertise of our teams.”
AirPro News analysis
Securing Part 145 approval for the Boeing 737 family represents a logical progression for JCB Aero as it matures its MRO footprint in southern France. By diversifying its capabilities to include both major narrowbody platforms, the facility reduces its exposure to single-manufacturer fleet dynamics. We view this dual-platform capability as a standard requirement for independent MRO providers seeking to maximize hangar utilization and attract mixed-fleet operators.
Sources: JCB Aero, AMAC Aerospace
Photo Credit: JCB Aero
MRO & Manufacturing
AnimaWings Selects SAMCO for A220 Base Maintenance
AnimaWings signs SAMCO as A220 base maintenance provider and inducts another A220-300 via Maastricht Aachen Airport.
Romanian operator AnimaWings has inducted another Airbus A220-300 into its growing fleet following the completion of livery and engineering work by SAMCO Aircraft Maintenance and MAAS Aviation. The aircraft’s release to service coincides with a formal agreement signed on September 3, 2026, designating SAMCO as the base maintenance provider for the airline’s A220 operations.
The preparation of the new narrowbody aircraft took place at Maastricht Aachen Airport (MST) in the Netherlands. According to a company statement, SAMCO partnered with neighboring facility MAAS Aviation to provide an integrated induction solution for the carrier.
Integrated maintenance and livery operations
The induction process required coordination between specialized aviation service providers at the Dutch airport. MAAS Aviation completed the aircraft painting and livery application, while SAMCO managed the regulatory and engineering requirements necessary for commercial operations.
SAMCO utilized its European Union Aviation Safety Agency (EASA) Part 21 approval to manage the workscope preparation and design elements of the induction. Following the physical painting process, the maintenance provider officially released the aircraft into commercial service under its Part 145 certification. In its announcement, SAMCO stated the co-located collaboration ensured a “smooth transition from the paint shop to the skies.”
AnimaWings fleet expansion and maintenance strategy
The recent aircraft delivery aligns with a broader operational partnership between the Romanian carrier and the Dutch maintenance, repair, and overhaul (MRO) provider. AviTrader reported that on September 3, 2026, AnimaWings officially selected SAMCO to provide tailored base maintenance services for its expanding Airbus A220 fleet to ensure long-term operational availability and reliability.
AnimaWings is currently executing a fleet modernization strategy with a stated target of operating 18 aircraft by the end of 2027. The airline has centered this growth on the Airbus A220-300. According to Skies Mag, the aircraft type delivers a 25% reduction in fuel burn and carbon dioxide emissions per seat compared to previous-generation aircraft, supporting the carrier’s efficiency targets.
AirPro News analysis
We view the co-location of specialized aviation services at regional hubs like Maastricht Aachen Airport as a significant advantage for growing carriers. By utilizing adjacent facilities for painting and engineering release, operators can minimize non-revenue repositioning flights and reduce overall aircraft downtime. For a carrier like AnimaWings scaling rapidly toward an 18-aircraft fleet, securing a dedicated base maintenance provider that can also manage induction workflows provides critical operational stability during a period of high growth.
Sources: SAMCO Aircraft Maintenance
Photo Credit: AnimaWings
MRO & Manufacturing
RECARO Aircraft Seating Launches R4 Premium Class Seat
RECARO officially introduced the R4 premium seat on Aug 25, 2026, with EASA certification for the Boeing 787.
RECARO Aircraft Seating officially introduced the R4 premium class seat on August 25, 2026, marking the successor to its decade-old PL3530 model. Initial deliveries of the new seating system began in June 2026, with entry into commercial service expected later in the year.
In a press release issued from its Schwaebisch Hall, Germany headquarters, the manufacturer detailed the R4’s focus on enhanced ergonomics, privacy, and accessibility. The seat is currently certified under European Technical Standard Orders (ETSO) by the European Union Aviation Safety Agency (EASA) for installation on the Boeing 787, with additional airframe certifications in progress.
Design and passenger experience upgrades
The R4 introduces several modern amenities designed to address evolving passenger expectations in widebody premium cabins. Key features include a six-way adjustable headrest with integrated neck support, side ambient lighting, and privacy wings equipped with an integrated reading light. For in-flight entertainment, the seat accommodates a 16-inch integrated monitor.
The design also incorporates functional workspace and connectivity improvements. Passengers have access to an extra-wide single-plate tray table featuring a soft open and close mechanism, an integrated Personal Electronic Device (PED) holder, and customizable power options. The seat features a side console with dedicated access designed specifically for Passengers with Reduced Mobility (PRM).
Strategic positioning and certification
The launch of the R4 builds upon the foundation of the PL3530, which RECARO originally introduced to the market in 2015. By securing initial ETSO certification for the Boeing 787, RECARO positions the R4 to capture widebody premium economy and regional business class retrofit and line-fit opportunities.
Mark Hiller, CEO and Shareholder of RECARO Aircraft Seating and CEO of RECARO Holding, highlighted the strategic importance of the new product line.
“We are proud to introduce the R4, the latest addition to our Premium Class portfolio. Building on the success of the PL3530, the R4 reflects our commitment to combining comfort, ergonomics, and premium features in a seating solution designed to meet the evolving expectations of both airlines and passengers.”
AirPro News analysis
The introduction of the R4 underscores a broader industry trend where seat manufacturers are elevating premium economy products to mirror the business class standards of previous decades. By integrating features like 16-inch monitors and enhanced privacy wings, we see RECARO directly targeting airlines looking to monetize the growing demand for premium leisure travel. The specific inclusion of PRM-accessible consoles also indicates a proactive approach to upcoming accessibility mandates in major aviation markets. Securing EASA certification for the Boeing 787 first is a logical entry point, given the aircraft’s heavy utilization on long-haul routes where premium seating demand is highest.
Sources: RECARO Aircraft Seating
Photo Credit: RECARO Aircraft Seating
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