Airbus, a global leader in the aerospace industry, has partnered with Autodesk, a pioneer in 3D design and engineering software, to develop the world’s largest 3D-printed airplane cabin component. This groundbreaking innovation marks a significant step forward in aviation manufacturing and sustainability.
The new component, called the “bionic partition,†was designed using custom algorithms that mimic natural structures like bones and cellular formations. The result is a lightweight yet highly durable structure that outperforms traditional manufacturing methods. The part was created using additive manufacturing techniques, which allow for complex geometries that would be impossible to achieve through conventional processes.
This bionic partition serves as a divider between the passenger seating area and the galley, and it also supports the jumpseat used by flight attendants. Given the strict design and weight requirements of aircraft components, this generative design approach was not only suitable but also optimal for achieving the desired performance and efficiency.
One of the most impressive aspects of this project is its environmental impact. The new partition is 45% lighter than existing models—equivalent to a 30 kg reduction. When applied across the entire cabin of Airbus’ A320 fleet, this design could lead to annual CO₂ emissions savings of up to 465,000 metric tons. That’s equivalent to removing around 96,000 cars from the road for an entire year.
The bionic partition is made from Scalmalloy®, a high-performance aluminum-magnesium-scandium alloy developed by APWorks, an Airbus subsidiary focused on additive manufacturing. This material is specifically engineered for 3D printing and offers superior strength and flexibility, making it ideal for use in critical aircraft components.
The success of this project was made possible by cloud computing and generative design. By leveraging powerful cloud-based computing resources, engineers were able to generate thousands of design alternatives, leading to optimized solutions that might not have been discovered through traditional methods. Additive manufacturing then brought these designs to life, proving that complex, efficient structures can now be produced at scale.
Jeff Kowalski, Chief Technology Officer at Autodesk, emphasized the significance of this achievement: “This isn’t just a theoretical experiment—it’s a real, functional component that will soon be flying in airplanes. Collaborations like this show what’s possible when we combine cutting-edge technology with innovative thinking.â€
Peter Sander, Vice President of Emerging Technologies and Concepts at Airbus, added: “We are always pushing the boundaries of what’s possible. This partnership with Autodesk, APWorks, and Concept Laser has demonstrated how new materials, generative design, and additive manufacturing can revolutionize the way we build aircraft. It's not just about efficiency—it's about creating a more sustainable future for air travel.â€
Testing of the bionic partition has already been completed successfully, and further trials, including a test flight, are planned for next year. The project is a joint effort between Autodesk, Airbus, APWorks, and The Living, an Autodesk studio that specializes in applying generative design and new technologies to real-world applications.
Autodesk is a global leader in design and engineering software, empowering professionals across industries to bring their ideas to life. From architects to engineers, artists to students, Autodesk provides tools that help solve complex challenges and drive innovation.
Airbus is one of the world’s top aircraft manufacturers, known for producing some of the most fuel-efficient and quiet aircraft available. With a wide range of models serving different market segments, Airbus continues to lead the way in aerospace innovation.
APWorks, a subsidiary of the Airbus Group, focuses on additive manufacturing and advanced materials, helping companies across various industries adopt cutting-edge production techniques.
The Living, an Autodesk Studio, explores the future of design by integrating generative design, biology, and new materials into real-world projects. In 2015, it was ranked among the World’s Most Innovative Companies in Architecture by Fast Company.
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