Stratasys Accelerates Airbus Production with Additive Manufacturing

More than 25,000 certified 3D-printed parts produced annually – over 200,000 already in flight

Airbus A350 at an airport; Copyright: Max_Leitmeier-Schwarzbild

Airbus’ Airspace Explorer – a specially configured A350-900 flight test aircraft fitted with the company’s award-winning Airspace cabin – is exhibited at the ILA Berlin air show Copyright: Max_Leitmeier-Schwarzbild

19.01.2026

Airbus is increasingly relying on Stratasys additive manufacturing technologies to support production and maintenance across its global fleet. Using the high-performance ULTEM™ 9085 CG material, more than 25,000 certified aircraft parts are produced each year, reducing downtime, strengthening supply chains and lowering storage costs.

Additive manufacturing scales across the Airbus fleet

Airbus now produces over 25,000 flight-ready 3D-printed components annually using Stratasys technology. What began with a spare crew-seat part has evolved into a broad application of polymer additive manufacturing, with more than 200,000 certified parts currently in service.

Recent data highlights significant efficiency benefits. For the Airbus A350, the use of Stratasys 3D-printed components resulted in a 43% weight reduction, removal of minimum order quantity (MOQ) requirements and an 85% shorter lead time, saving both cost and production time.

High-performance materials for aerospace

Airbus manufactures components for its A320, A350 and A400M platforms using ULTEM™ 9085 Filament Certified Grade (CG) on multiple Stratasys industrial FDM® systems. These parts meet stringent aerospace requirements and enable faster, more cost-effective replacement of mission-critical components.

“Stratasys’ additive manufacturing technology is an integral part of our commitment to safe and sustainable aviation,” said Serge Senac, Airbus Industrial Leader for Polymer Additive Manufacturing.

The flexibility of additive manufacturing supports Airbus in strengthening its connected value chain and aligns with long-term sustainability goals.

Did you know?

Distributed manufacturing enables on-demand production exactly where components are needed – for example at major hubs to minimise aircraft downtime.

Unlike traditional manufacturing, which requires tooling and moulds, additive processes allow production to start almost immediately.

While subtractive methods remove material, additive manufacturing uses only what is required – especially beneficial when working with high-performance polymers.

Advantages of distributed manufacturing

By producing parts when and where they are needed, Airbus can:

reduce aircraft downtime
minimize warehousing needs
lower risks associated with global supply chains

“Our collaboration with Airbus is proof that additive manufacturing is being integrated into true production at scale, and can be a huge differentiator,” said Rich Garrity, Chief Business Unit Officer, Stratasys.

Decades of aerospace expertise

Stratasys brings extensive experience in delivering certified materials, additive manufacturing platforms and software solutions for OEMs and suppliers. Its technologies support both production and MRO applications, helping aerospace stakeholders maintain operational reliability while managing costs.

Stratasys

At a glance

Airbus now produces more than 25,000 certified 3D-printed parts per year using Stratasys technology, with over 200,000 components already in service. The use of ULTEM™ 9085 CG delivers a 43% weight reduction, 85% shorter lead times and greater supply chain resilience.

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