Case Study: Airbus Defence and Space achieves industrial-scale deployment of additively manufactured RF components with 3D Systems

Airbus Deploys Additive Manufacturing for RF Components with Help from 3D Systems

Airbus Defence and Space in Portsmouth developed novel switch assembly networks for RF passive hardware destined for two Eurostar Neo spacecraft for Eutelsat, but faced a demanding engineering challenge: very high accuracy, thin walls combined with large mass concentrations, and the need to reduce weight, part count and assembly labor. The program represented one of the first large‑scale deployments of direct metal printing (DMP) for RF components, requiring careful risk assessment and industrialization planning.

3D Systems worked with Airbus from early design-for-AM (DfAM) consultation through prototyping, qualification and production support, co‑engineering a reliable manufacturing flow. Parts were printed in LaserForm® AlSi10Mg on DMP Factory 350 machines at 3D Systems’ AS9100‑certified Leuven facility, using a phased qualification approach and tight process controls. The collaboration delivered a significant number of complex metal AM parts, achieved weight and part‑count reductions, cut assembly labor, and enabled industrialized, repeatable production of RF components.

Airbus Defence and Space

Gareth Penlington

Payload Manager