Emirates employs 3D printing to manufacture aircraft parts

Emirates, US-based 3D Systems and French aviation engineering company UUDS have applied 3D printing technology to manufacture components for aircraft cabins.

As part of the partnership, Emirates has used 3D Systems’ selective laser sintering (SLS) technology platform to manufacture the first batch of video monitor shrouds.

Emirates engineering support services senior vice-president Ahmed Safa said: “Over the last two years, Emirates Engineering has been actively exploring 3D printing for aircraft cabin parts as it is a transformational technology that can be used to achieve an increase in efficiency and productivity.

“We worked with a number of suppliers to develop prototypes of 3D printed cabin parts but ultimately decided on working with 3D Systems and UUDS.”

3D Systems’ SLS technology employs lasers to integrate powdered plastic into the required shape defined by a 3D model and is different from the Fusion Deposition Modelling (FDM) technique usually used to 3D print aircraft parts.

“We worked with a number of suppliers to develop prototypes of 3D printed cabin parts but ultimately decided on working with 3D Systems and UUDS.”

It could also help Emirates to reduce fuel emissions and costs when consolidated over its entire fleet of aircraft.

3D Systems’ latest DuraformProX FR1200 thermoplastic has been used to 3D print Emirates’ new video monitor shrouds, which weigh up to 13% lighter than the components manufactured using conventional FDM technique.

Emirates’ 3D printed video monitor shrouds have already undergone various structural, durability, flammability and chemical tests and are currently in process of receiving airworthiness certification from European Aviation Safety Agency (EASA).

After receiving the certification, Emirates plans to install the video monitor shrouds on selected aircraft to collect data as part of tests for onboard durability and wear and tear.

In addition, Emirates and UUDS have developed 3D-printed aircraft cabin air vent grills that have already received EASA certification and been installed on aircraft for onboard trials last month.

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