Emirates pioneers 3-D printing for aircraft parts

Emirates has used cutting-edge 3-D printing technology to manufacture components for its aircraft cabins.

The airline, which placed a US$15.1 billion order for 40 Boeing Dreamliners at the Dubai Airshow this week, said it had reached a significant milestone by using selective laser sintering (SLS), a new 3-D printing technique to produce video monitor shrouds.

Emirates worked with 3D Systems, a US-based 3-D printing equipment and material manufacturer and services provider, and with UUDS, a European aviation engineering and certification office and services provider based in France, to print the first batch of video monitor shrouds using 3D Systems’ (SLS) technology platform.

Emirates worked with UUDS to develop 3-D printed aircraft cabin air vent grills that have received EASA certification and have already been installed on aircraft for onboard trials.

The SLS technology uses lasers to bind together powdered plastic into the required shape defined by a 3-D model and is different from the fusion deposition modelling (FDM) technique normally used for printing aircraft parts. The material used to print Emirates’ video monitor shrouds is a new thermoplastic developed by 3D Systems – Duraform ProX FR1200 – with excellent flammability resistance properties and surface quality suitable for commercial aerospace business applications, Emirates said.

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

“We worked with a number of suppliers to develop prototypes of 3-D printed cabin parts but ultimately decided on working with 3D Systems and UUDS. The technology we use has the potential to deliver cabin parts with reduced weight without compromising on structural integrity or cosmetic appeal.”

Video monitor shrouds that are 3-D printed using the SLS technique can weigh between 9 and 13 per cent less than those manufactured traditionally or through the FDM technique. This has the potential to lead to significant reductions in fuel emissions and costs.

Emirates’ 3-D printed video monitor shrouds have undergone a range of structural, durability, flammability and chemical tests and are also in the process of receiving EASA certification for airworthiness for aircraft interior cabin parts, the carrier said. On receiving EASA certification the shrouds will be installed on select aircraft in the fleet.

Emirates said it will continue to pursue other opportunities for introducing 3-D printed components across its operations.