Additive manufacturing (AM) has transitioned from prototyping to mainstream production in aviation maintenance, repair, and overhaul (MRO) operations. MRO providers leverage AM for certified aircraft components, including cabin fittings and structural parts, enhancing supply chain resilience and enabling localized production.
Lufthansa Technik’s Hamburg AM center produces load-bearing metal parts beyond cabins and polymer components for interiors. Company spokesperson Michael Lagemann states: “These range from parts hidden in the background… to much more ‘visible’ components such as seat covers or ‘occupied’ signs for restrooms.” They also 3D-print headset holders and maintenance tools, like a device simplifying water filter replacements without full assembly removal.
MROs start with polymer cabin parts due to frequent wear, high costs, and long lead times from obsolescence. Stephan Keil of EOS notes: “Obsolescence and supply chain challenges cause long lead times, while the cost of conventional injection moulding tools translates into high prices for small runs.” AM extends to cabin systems like air distribution, restrooms, passenger service units, seat actuators, and structures.
Key drivers include complex geometries without special tooling, lightweight designs via customization, and supply chain agility. Lagemann explains: “Instead of sending a cabin component from Hamburg to a facility abroad, we could transfer the data… and have local colleagues print the required component themselves.”
Regulatory compliance requires design organizations (DOs) for prototypes and production organizations (POs) for quality. Keil adds: “The DO must be authorised to design AM components, while the PO must be authorised to manufacture using AM technology.” EASA demands full traceability; approvals use EPA in Europe or PMA in the US, matching OEM standards.