Satair Provided Metal Printed Flying Spare Part


Satair, an Airbus services company, has provided one of its airline customers in the US with what is believed to be the first certified metal printed flying spare part. This A320ceo specific part is no longer procurable from the original supplier, thus leading to an alternate solution developed by Satair. The tailored additive manufactured solution reduces the likelihood of an AOG for this specific aircraft, and on a larger level leads to an increased flexibility in part production while meeting the same high quality standards ensured by EASA Form1 certification.


The A320ceo wingtip fences are installed in four different versions – starboard, port, upper and lower. These parts are A320ceo specific and no longer in production. The spare parts supplier had difficulties providing the cast part. This led to a regular loss of the moulds, resulting in a potentially high investment cost for Satair to replace the moulds for individual orders. Satair also studied other conventional options such as re-designing the part for machining technology, but the resulting cost and lead-time implications were not competitive.


Felix Hammerschmidt, HO Additive Manufacturing Satair, explained: “We received an order for replacement parts and our AOG procurement department turned to the Additive Manufacturing (AM) team for a solution. After a short pre-assessment, the part was handed over to the RapidSpares design offices at Airbus. Using a new certification process they were able to re-certify the former cast part within five weeks and adapt it to titanium, which is a qualified airworthy additive manufacturing material“. He added: “The lead time for certification is expected to reduce even further in the future once the technology becomes more of a standard.



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