Case Study: Emirates achieves 9–13% lighter cabin parts and supply-chain efficiency with 3D Systems

Emirates Uses SLS Printing For Better Fuel Economy and Supply Chain Efficiency

Emirates partnered with 3D Systems to reduce weight and improve supply‑chain efficiency for high‑turnover cabin components—most notably seatback video monitor shrouds—while meeting stringent aviation safety and flame‑retardancy standards. The airline needed a fit‑for‑purpose solution that could be rapidly produced at scale, certified for airworthiness, and deliver measurable operating‑cost and fuel‑efficiency benefits across its fleet.

Using a scan‑based reverse‑engineering workflow (FARO scan + Geomagic Design X) and 3D Systems’ selective laser sintering (SLS) with DuraForm ProX FR1200 flame‑retardant nylon, Emirates produced parts that are 9–13% lighter than conventional counterparts. The approach enables faster, nested production and on‑demand manufacturing, reduces inventory needs, meets aviation certification requirements, and promises significant cost and fuel‑emission savings as parts move into onboard trials and full approval.

Emirates

Ahmed Safa

Senior Vice President, Engineering Support Services