Airbus Integrates Large Titanium w-DED Parts in A350

Airbus has begun serial integration of large titanium components produced using wire-Directed Energy Deposition (w-DED), marking a category first for industrial-scale additive manufacturing of primary aircraft structures. The initial application is on the A350, where the technology replaces traditionally forged parts in the cargo door surround area.

w-DED is an additive process in which a multi-axis robotic system feeds titanium wire into a focused energy source—such as plasma, laser, arc, or electron beam—to melt and deposit material layer by layer. Guided by a digital model, the process builds a near-net-shape “blank” that requires only limited final machining to reach design tolerances.

Compared with powder-bed metal 3D printing, which is typically limited to small components, w-DED enables the production of large structural parts up to seven metres in length. Deposition rates increase from hundreds of grams per hour to several kilograms per hour, making the process viable for higher-volume manufacturing of load-bearing aircraft structures.

A key driver is material efficiency. Titanium is critical in modern aircraft due to its strength-to-weight ratio and compatibility with carbon-fibre composites, but it is also a high-value material. Conventional forging and machining can result in buy-to-fly ratios where 80–95% of the original material is removed and recycled. By growing components close to their final geometry, w-DED significantly reduces raw material waste at source.




The process also shortens development cycles. Traditional die forging requires complex tooling with lead times that can extend to two years. In contrast, w-DED relies on digital toolpaths, allowing design changes to be implemented within weeks. This agility supports rapid iteration during aircraft development, particularly in early build phases.

For the A350 application, Airbus-designed parts were produced by a qualified supplier using plasma w-DED, ultrasonically inspected by Testia Bremen, then machined and installed in Airbus facilities. The printed components are functionally and geometrically equivalent to their forged predecessors while delivering immediate cost benefits.

Looking ahead, Airbus plans to extend w-DED from this initial application to more critical structures across other programmes, including potential future use in wings and landing-gear components. The technology also enables “designed for DED” approaches, allowing engineers to consolidate multiple assemblies into single printed parts, simplifying supply chains and reducing assembly effort.

Development is being pursued at group level, with Airbus and partners evaluating multiple energy sources and both in-house and outsourced production models, with the aim of establishing w-DED as an industrial standard across future aircraft platforms.

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