Emirates Embraces 3D Printing for Aircraft Cabin Parts, Boosting Efficiency and Sustainability

Emirates has announced the deployment of Selective Laser Sintering (SLS) technology to manufacture video monitor shrouds for its aircraft cabins. This follows the airline’s October trial of 3D‑printed cabin air vent grills, developed in partnership with the European Aviation Safety Agency (EASA).

Aerospace: Leading the Way

The aerospace sector has long been at the forefront of adopting additive manufacturing for end‑use parts. In April, Boeing incorporated 3D‑printed titanium components into its 787 Dreamliner, becoming the first manufacturer to use 3D‑printed structural titanium parts on an aircraft and achieving savings of up to $3 million. Earlier this summer, Lockheed Martin invested $1 million in a dedicated 3D‑printing lab to accelerate the development of future aerospace components.

For its latest initiative, Emirates partnered with U.S. printer maker 3D Systems. Using 3D Systems’ SLS technology and Duraform® ProX® FR1200 thermoplastic, the airline produced the video monitor parts that now populate its cabin interiors.

Why SLS?

SLS offers a suite of advantages for airlines. It yields lighter parts, directly contributing to fuel‑efficiency and reduced CO₂ emissions. The process can print multiple components simultaneously without the need for support structures, eliminating material waste and accelerating lead times. Importantly, SLS enables on‑demand, one‑off production, allowing Emirates to streamline inventory management and reduce the need for large spare‑part stocks.

All printed components undergo rigorous testing for flammability, durability, and chemical resistance. They are currently awaiting EASA airworthiness certification, and Emirates has committed to ongoing performance evaluations.

As the airline continues to assess the benefits of 3D‑printed parts, the future may see entire aircraft cabins fabricated with additive manufacturing—promising a new era of design flexibility and operational efficiency.