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Airbus, the global leader in aviation, has teamed up with Autodesk, a pioneer in 3D design and engineering software, to produce the world's largest 3D-printed airplane cabin component. Known as the "bionic partition," this component was crafted using advanced algorithms that mimic natural structures such as cellular patterns and bone growth, and was subsequently manufactured via additive manufacturing techniques. This innovative design and production method results in a structure that is both stronger and lighter than conventional methods could achieve.
Attached you'll find an image titled "01-Bionic-Partition." The partition serves as a divider between the seating area and the galley of the plane, and also supports the jump seat for cabin crew members. Like many aircraft parts, the partition demands exceptional design and structural integrity, including specific cutouts and weight restrictions, making the generative design approach highly suitable.
Innovative Materials and Production Techniques Lead to Fuel Efficiency Gains
In aviation, cutting down on weight directly translates to reduced fuel consumption. The Airbus bionic partition, shaped in a micro-lattice configuration that is both structurally robust and lightweight, is 45 percent (30 kg) lighter compared to existing models. If implemented throughout the cabin and across the current backlog of A320 planes, Airbus estimates that this new design approach could save up to 465,000 metric tons of CO2 emissions annually, which is equivalent to removing approximately 96,000 cars from the roads for a year.
The new bionic partition utilizes Scalmalloy®, a second-generation aluminum-magnesium-scandium alloy developed by APWorks, an Airbus subsidiary specializing in additive manufacturing and advanced materials. Scalmalloy® is engineered specifically for 3D printing and boasts superior mechanical properties, allowing it to stretch further before breaking. This marks the first time it has been used on a large scale within an aircraft component.
Generative Design Enabled by Cloud Computing Power
The capability to leverage countless central processing units (CPUs) through cloud computing has brought about significant advancements in design and engineering. Generative design takes advantage of cloud power to compute vast sets of design options—hundreds to thousands—that meet specific objectives and constraints. By exploring novel solutions that seasoned designers may not have considered, generative design enhances both design quality and performance. Given that these designs are nearly impossible to produce using traditional methods, additive manufacturing techniques like 3D printing are vital to 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 of Autodesk. "This isn’t just a theoretical exercise—it’s a fully functional component we can anticipate seeing installed in aircraft very soon. We’re excited to continue collaborating with Airbus on new components and designs for both current and future aircraft."
Peter Sander, Vice President of Emerging Technologies and Concepts at Airbus, added: "At Airbus, we are always pushing the limits of new technologies and exploring ways to foster innovation. Our collaboration with Autodesk, APWorks, and Concept Laser has been extremely fruitful. Autodesk brings generative design expertise and a deep understanding of additive manufacturing, which is essential for turning great concepts into tangible products. These technologies will ultimately transform how we design and build aircraft, leading to improvements in fuel efficiency, passenger comfort, and a substantial reduction in the environmental impact of air travel."
Initial testing of the partition has been successfully completed. Further testing 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 known for applying generative design and new technologies across various fields and applications.
For more information about Autodesk, visit autodesk.com or follow @autodesk.
Airbus is a leading aircraft manufacturer offering the most modern and comprehensive family of airliners on the market, ranging from 100 to over 500 seats. Airbus leads the way in innovative technologies and provides some of the world’s most fuel-efficient and quiet aircraft. With over 16,000 aircraft sold to more than 380 customers globally, Airbus has delivered over 9,400 aircraft since the first Airbus entered service. Headquartered in Toulouse, France, Airbus has 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.
As a 100% subsidiary of the Airbus Group, APWorks is well-versed in modern manufacturing processes. It functions as a technical consultancy and production hub for additive manufacturing. Beyond its primary focus 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.
The Living, an unprecedented Autodesk Studio, explores the future by prototyping it today. The Studio applies generative design, biology, and new materials to real-world construction projects within 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 information, visit thelivingnewyork.com.