Boeing 787 Dreamliner to Save $3M per Plane with 3D-Printed Titanium Parts
How Additive Manufacturing is Cutting Costs for Aerospace Giants
Boeing has partnered with Norsk Titanium AS to produce the first 3D-printed structural titanium parts for its 787 Dreamliner, a groundbreaking move expected to reduce manufacturing costs by $2–3 million per aircraft. This collaboration marks a pivotal shift toward industrial adoption of additive manufacturing in aerospace.
Key Benefits of 3D-Printed Titanium Components
- Cost Efficiency: Titanium alloy, while lightweight and strong, is seven times more expensive than aluminum, accounting for roughly $17 million of a Dreamliner’s $265 million price tag.
- Weight Reduction: The 787’s carbon-fiber fuselage and wings require more titanium than conventional planes, making 3D printing an ideal solution.
- Streamlined Production: Norsk Titanium’s Rapid Plasma Deposition™ (RPD) technology minimizes material waste compared to traditional forging.
The Road to Certification and Scalability
Norsk Titanium spent over a year collaborating with Boeing to design and secure Federal Aviation Administration (FAA) certification for four critical 787 components. Once the FAA approves the material properties and production process later this year, Norsk anticipates a surge in demand:
- Mass Production Potential: Thousands of additional parts could be printed without individual FAA approvals, accelerating cost savings.
- U.S. Expansion: The company plans to operate nine printers at its 67,000-square-foot Plattsburgh, New York facility by year-end.
Industry-Wide Implications
This milestone isn’t just about cost savings—it’s a testament to the durability and reliability of 3D-printed metal parts in high-stress aerospace applications. While GE has used 3D printing for engine fuel nozzles, Boeing’s adoption of printed structural airframe components sets a new precedent.
Boeing’s Financial Turnaround
The 787 Dreamliner became profitable in 2023 after $29 billion in cumulative losses. By integrating additive manufacturing, Boeing aims to further optimize production and compete more effectively with Airbus’s A350, which also relies heavily on titanium.
The Future of Aerospace Manufacturing
As Norsk Titanium’s VP of Marketing, Chip Yates, noted:
“You’re talking about tons of titanium being printed instead of forged—literally.”
This shift underscores a broader trend: 3D printing is no longer a prototype technology but a cornerstone of modern aerospace efficiency.
(Source: Reuters, edited for clarity and SEO optimization)
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