Aviation

British Airways is exploring the possibility of using 3D printers to create aircraft parts in the future

BRITISH AIRWAYS TRIALS 3D PRINTING TO IMPROVE PUNCTUALITY AND REDUCE EMISSIONS CAUSED BY FLYING SPARE PARTS AROUND THE WORLD

British Airways’ tech experts say the possibilities for 3D printing in aviation are limitless and share predictions of how 3D printers could transform the industry
In the future machines could routinely be used to create aircraft parts, reducing delays for customers
Initiative is part of airline’s flightpath to net zero carbon emissions by 2050

British Airways is exploring the possibility of using 3D printers to create aircraft parts in the future. These printers would be located at airports around the world to reduce delays for customers and emissions caused by transporting items.

The airline’s innovators predict that non-essential cabin parts will be first on the list to be generated, including pieces of tray tables, entertainment systems and toilets. While these components do not impact the safe operation of the flight, they can reduce the number of seats or toilets available for customers and cause delays as engineers wait for the parts to be flown to wherever the aircraft is.

Ricardo Vidal, Head of Innovation at British Airways, says this area of technology has never been more important to ensure sustainability and a seamless travel experience: “We work with start-ups and innovation partners from around the world to explore and implement the very latest technologies, from artificial intelligence to speed up turnaround times to biometrics, helping us to deliver a seamless airport experience for customers. 3D printing is yet another advancement that will keep us at the forefront of airline innovation.”

3D printing is an essential step towards the sustainable future of aviation, as the printers can produce parts that, while as strong and durable as traditional components, weigh up to 55 per cent. Every kilogram removed saves up to 25 tons of CO2 emissions during the lifespan of an aircraft.

Watch a time-lapse of a model of the airline’s A350 being printed

British Airways’ exploration of 3D printing follows the airline’s BA2119: Flight of the Future programme in celebration of it’s centenary. It’s research into the future of the customer experience suggested that within the next decade, biological scanners gathering travellers’ physiological and nutritional needs could suggest food and drink to meet individual requirements and print these on board the aircraft. In addition, the research predicts that jet lag could become be a thing of the past, with 3D printers producing personalised health supplements.

British Airways’ top ten predictions for how 3D printing could be used by airline’s in the future:

1. Cutlery

2. Products for amenity kits, such as toothbrushes or combs

3. Tray tables

4. Aircraft windows

5. Inflight entertainment screens

6. Seats

7. Baggage containers

8. Circuit boards for electrical components

9. Flight deck switches

10. Aircraft shells

Aviation

Lost Tool Found in Qantas A380 After 34 Flights

An Australian Transportation Safety Bureau (ATSB) investigation recently revealed that a Qantas A380 operated 34 flights with a 1.25-meter nylon tool lodged in one of its engines.

This turning tool, used during borescope inspections to rotate the intermediate-pressure compressor, was left behind during scheduled maintenance at Los Angeles on December 6, 2023. It remained inside the engine until it was discovered by maintenance staff during a subsequent check at Los Angeles on January 1, 2024.

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The ATSB report highlights two critical lapses. First, maintenance engineers failed to notice the tool during final checks for foreign objects after the borescope inspection. Second, the lost tool procedure was not activated when the tool was identified as missing.

The certifying engineer ultimately cleared the aircraft for service without accounting for the misplaced tool. During the time qantas films the tool was inside, the A380 completed 34 flight cycles, accumulating nearly 294 hours without any noticeable effect on engine performance.

Although the tool was deformed by high-energy airflow within the engine, there was no reported damage to the engine itself. ATSB Chief Commissioner Angus Mitchell commented.

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“This incident underscores the importance of following established maintenance protocols. Engineers missed the tool during foreign object checks, and the required lost tool procedure wasn’t started after realizing the tool was missing.”

Following the investigation, the airline issued a safety directive, urging all engineering and tool storage teams to adhere strictly to these protocols to prevent similar incidents in the future.

A qantas spokesperson stated, “While the tool didn’t impact engine performance, we take this incident very seriously. It is critical to follow the correct lost tool procedures.”