Safran Expands Additive Manufacturing for Flight-Critical Aircraft Engine Parts

Safran, a major player in the aerospace and defense sector, is integrating additive manufacturing (AM) at the core of its development efforts, particularly within the CFM RISE program it shares with GE Aerospace. The company has already successfully introduced 14 AM part references into serial production since 2017 and plans to add over 10 new components with the RISE program. This strategic move aims to leverage AM's capabilities to reduce production times and complexity for critical engine parts.

The Safran Additive Manufacturing Campus, a 12,500 square meter facility inaugurated in October 2022, serves as the hub for these operations. This centralized campus consolidates the entire AM production chain, from research and development to part manufacturing and workforce training. It houses over 12 Laser Powder Bed Fusion (L-PBF) machines and 4 Directed Energy Deposition (DED) machines for production, along with additional printers for research and technology. Since its opening, the campus has produced over 111,000 AM parts, with more than 4,000 produced annually. Fourteen part references, including those with Class B criticality, have been certified and are in serial production, utilizing a range of alloys including titanium, nickel, aluminum, iron, and copper.

The CFM RISE program, focused on developing engines with over 20% lower fuel consumption, highlights Safran's commitment to AM. The company aims for 3D-printed components to constitute 25% of the program's production. AM enables the consolidation of multiple parts into a single component, significantly reducing assembly complexity and part count. For example, a turbine rear frame, previously made from six welded cast components, is now produced as a single piece. This transition has drastically cut production time from 18 months to approximately three weeks, with a future target of one week for serial production.

Beyond design simplification, mass reduction is another key driver for Safran's AM adoption, with weight savings ranging from 10% to 60% compared to traditional manufacturing methods. The e-APU 60 turbine stator, for instance, saw a 35% mass reduction and was consolidated from eight parts to four. Similarly, a hydraulic manifold unit and an A380 box beam achieved a 40% mass reduction. Life cycle assessments indicate that the mass savings of AM parts, leading to reduced in-service emissions, have a greater environmental benefit than the manufacturing process itself. Furthermore, AM supports supply chain sovereignty, enabling domestic or European production for defense contracts, such as the M88 bearing support for the Rafale fighter jet.