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3D Printing Lends Wings to Aerospace Spares

As per Gartner estimates, by 2020, 75% of manufacturing operations worldwide will be using 3D-printed tools, jigs and fixtures made in-house or by a service bureau to produce finished goods. 3D printing, or additive layer manufacturing (ALM), is redefining the contours of aircraft component manufacturing and taking digitization to the skies. It is being increasingly perceived as an “alternate technology” for aerospace aftermarket that not only helps ramp up production, but also produces parts, that are highly customized and demand short lead times, in a cost effective manner.


Wipro with its end-to-end engineering R&D and consulting services to manufacturers helps create high precision 3D printed parts and free form of designs within very short timelines. Wipro also believes that to maximize the potential of 3D printing, the additive manufacturing industry can look at three key areas of building parts - New design, Repair & overhaul, and Aftermarket.

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Our approach to 3D printing is unique and consists of 3 stages i.e. Assessment, AI assisted “Drawings to Data” and Design.

Download this paper to learn more about how you can leverage 3D printing to bring about changes in the manufacturing landscape of your industry.

Aerospace is not lagging behind in terms of early adoption of 3D printing technology, as you read this article a satellite antenna support is orbiting the earth and it’s been doing so since April 2015 thanks to TurkmenAlem, a telecommunication company. In addition to TurkmenAlem, Thales has just finished the printing of the biggest DMLS aluminium part printed in Europe with two antenna support for satellites Koreasat 5A and Koreasat 7. Light yet complex 3d printed parts like these ones are extremely interesting in aerospace because sending a kilogram to space costs 21500€ on Ariane 5 and the total available weight is very limited.

3D printed parts on board

While there are several niche markets all with their own ideas regarding how 3D printing can change their businesses but what most people want to know is: “when will 3D printing be used in commercial aircrafts”?

We have two very good examples from GE:

First, the housing for the T25 temperature and pressure sensor on the GE90 engine. The previously designed part was covered by ice which shed into the compressor, damaging it. GE redesigned the housing but the resulting complex form could only be produced through 3D printing. As GE has a long experience in 3D printing with 2 factories and a 3.5 billion $ investment over 5 years, it directly went to production and is currently being retrofitted on 400 Boeing 777.


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