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3D-printed titanium parts could save Boeing up to $3 million per plane

3D-printed titanium parts could save Boeing up to $3 million per plane

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The parts are the first structural airplane components to be approved by the FAA

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The 3D-printed parts produced by Norsk Titanium.
The 3D-printed parts produced by Norsk Titanium.
Image: Norsk Titanium

3D printing may not be the home phenomenon many hoped for, but the technology continues to find a place in the world of industrial manufacturing. Reuters reports that Boeing will start using 3D-printed titanium parts in the construction of its 787 Dreamliner jet airliner. These are the first 3D-printed structural components to be approved by the Federal Aviation Authority, says manufacturer Norsk Titanium, and could eventually save Boeing up to $3 million in construction costs on each jet built.

These cost savings are important for Boeing, which lost money on each 787 built until last year. This is quite normal for commercial jet programs, which sink a lot of money into initial research and engineering, before trimming expenses by making the manufacturing process more efficient. Production of the Dreamliner only became profitable in 2016 after Boeing racked up some $29 billion in losses.

A 787-9 Dreamliner (with longer fuselage) built for Air New Zealand.
A 787-9 Dreamliner (with longer fuselage) built for Air New Zealand.
Photo by Stephen Brashear / Getty Images

The 787 is particularly worrying cost-wise due to its extensive use of titanium. This metal alloy is strong, lightweight, and helps to keep the plane fuel efficient, but costs seven times more than aluminum, which is commonly used in commercial jets. As of 2015, Boeing lost $30 million on the cost of each $265 million Dreamliner, with titanium parts accounting for $17 million of the overall price tag.

3D-printing helps to bring these costs down. Norsk has developed its own technology for creating titanium parts, using a technique named Rapid Plasma Deposition or RPD, in which titanium wire is melted in a cloud of argon gas to create each part. This process cuts down on both raw material costs and energy usage compared to traditional forging and machining, says Norsk, making each jet cheaper to build.

Norsk’s 3D-printed titanium parts before and after the final machining process.
Norsk’s 3D-printed titanium parts before and after the final machining process.
Image: Norsk Titanium

Boeing is no stranger to using 3D-printed parts (it’s previously deployed them in jet engines and its space taxis), but Norsk says its products are the first approved by the FAA as structural, load-bearing components. Later this year, the company expects to get its entire manufacturing process approved, rather than each individual part, allowing it to produce even more parts for Boeing and other firms. This will “open up the floodgates” for 3D-printed titanium in commercial jets, Chip Yates, Norsk Titanium's vice president of marketing, told Reuters.