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Airbus, the renowned aircraft manufacturer, has teamed up with Autodesk, a leader in 3D design and engineering software, to create the world's largest 3D-printed airplane cabin component. Known as the "bionic partition," this component was developed using custom algorithms that mimic natural structures like cellular patterns and bone growth. It was then fabricated using advanced additive manufacturing techniques. This innovative design and production method results in a structure that is both stronger and lighter compared to traditional manufacturing processes.
Attached is an image of the bionic partition. The partition acts as a divider between the seating area and the galley of the plane, also supporting the jumpseat for flight attendants. Like many aircraft parts, it has strict design and structural demands, including specific cutouts and weight limitations, making the generative design approach highly suitable.
Innovative Materials and Production Techniques Lead to Fuel Efficiency
In aviation, reducing weight translates directly to fuel savings. Designed in a structurally robust yet lightweight micro-lattice pattern, Airbus' new bionic partition is 45% (30 kg) lighter than existing models. If implemented throughout the cabin and across the current backlog of A320 planes, Airbus estimates that this new design could save up to 465,000 metric tons of CO2 emissions annually, equivalent to removing approximately 96,000 passenger vehicles from the road for a year.
The bionic partition uses Scalmalloy®, a second-generation aluminum-magnesium-scandium alloy developed by APWorks, an Airbus subsidiary specializing in additive manufacturing and advanced materials. Scalmalloy® is specifically designed for 3D printing and boasts excellent mechanical properties, allowing it to stretch further before breaking. This marks the first time this material has been used on such a large scale within an aircraft component.
Generative Design Enabled by Cloud Computing Power
The capability to leverage vast numbers of central processing units (CPUs) through cloud computing has opened up remarkable advancements in design and engineering. Generative design utilizes the cloud to calculate extensive sets of design alternatives—ranging from hundreds to thousands—that meet specific objectives and constraints. This approach can uncover novel solutions that seasoned designers might overlook, enhancing design quality and performance. Given that these designs are nearly impossible to produce using conventional methods, additive manufacturing techniques like 3D printing are essential for the success of generative design.
"Generative design, additive manufacturing, and the development of new materials are already reshaping the landscape of manufacturing, and innovative companies like Airbus are demonstrating what's possible," said Jeff Kowalski, Chief Technology Officer at Autodesk. "This isn't just a theoretical exercise—it's a fully functional component we can expect to see installed in aircraft soon. We're excited to continue collaborating with Airbus on new components and designs for current and future aircraft."
Peter Sander, Vice President of Emerging Technologies and Concepts at Airbus, added: "At Airbus, we're always pushing the boundaries of new technologies and exploring ways to innovate. Our collaboration with Autodesk, APWorks, and Concept Laser has been highly successful. Autodesk brings generative design technology and a deep understanding of additive manufacturing, which is vital for turning great concepts into tangible products. These technologies will fundamentally change how we design and build aircraft, leading to improvements in fuel efficiency, passenger comfort, and a significant reduction in the environmental impact of air travel overall."
Initial testing of the partition has been successfully completed. Further trials will take place next year, including a test flight.
The bionic partition project is a collaborative effort involving Autodesk, Airbus, APWorks, and The Living, an Autodesk studio that specializes in applying generative design and new technologies across various fields and applications.
About Autodesk:
Autodesk aids individuals in imagining, designing, and creating a better world. From design professionals and engineers to architects and digital artists, students, and hobbyists, everyone uses Autodesk software to unleash their creativity and tackle significant challenges. Visit autodesk.com or follow @autodesk for more information.
About Airbus:
Airbus is a leading aircraft manufacturer with the most modern and comprehensive family of airliners available, accommodating capacities from 100 to over 500 passengers. Airbus advocates for innovative technologies and offers some of the world’s most fuel-efficient and quiet aircraft. Airbus has sold more than 16,000 aircraft to over 380 customers globally. Since the first Airbus aircraft entered service, more than 9,400 deliveries have been achieved. Airbus is headquartered in Toulouse, France, with design and manufacturing facilities in France, Germany, the UK, and Spain, along with subsidiaries in the U.S., China, India, Japan, and the Middle East.
About APWorks:
As a 100% subsidiary of Airbus Group, APWorks is well-versed in contemporary manufacturing processes. It serves as a technical consultancy and a production hub for additive manufacturing. Besides focusing on additive manufacturing, APWorks makes innovative projects, ideas, technologies, and concepts from Airbus Group Innovations, the corporate research network, accessible to clients across all industries.
About The Living:
The Living, a pioneering Autodesk Studio, explores the future by prototyping it today. The Studio applies generative design, biology, and new materials to real-world construction projects in the context of technology, culture, and the environment. In 2015, The Living was ranked third by Fast Company in its list of the World’s Most Innovative Companies in Architecture. For more details, visit thelivingnewyork.com.