Safran Engineering Services offers metal and polymer 3D printing for aerospace parts

Safran Engineering Services, the engineering services arm of Safran Group, now offers additive manufacturing support for aeronautical part design and production, covering both metal and polymer 3D printing. The offering spans design, materials qualification, supplier management, and parts manufacturing, and the company positions it around part weight reduction, consolidation of part counts, and faster product development cycles. Safran cites a 25 percent mass savings compared to original parts as a benchmark result of the process.

On the design side, Safran Engineering Services proposes what it calls a “black metal” redesign, along with new part design and topology optimization for parts it identifies as eligible for additive manufacturing. The company also offers bionic and lattice shape proposals, along with additive manufacturing solutions for tooling.

Safran Engineering Services runs materials characterization and approval plans for additive manufacturing, backed by laboratory test support and control assessments. Its product development support extends into supply chain management: the company defines part or system functional requirements, drafts specifications, consults and rates suppliers against customer purchasing and quality standards, and manages the process from printed part through to finished, accepted components.

On production, Safran Engineering Services draws on its own manufacturing capacity and a network of manufacturing partners to produce parts across a range of additive manufacturing technologies, in both metal and polymer materials. Output covers prototypes, test samples, demonstrators, and pre-series and serial parts.

Companywide, Safran has put additive manufacturing to work across a range of engine and aircraft components. At the 2025 Paris Air Show, the company showcased a 3-foot turbine rear frame for its RISE engine program, produced via large-scale additive manufacturing and roughly one-third lighter than the traditional equivalent.

On the propulsion side, Safran Helicopter Engines produces fuel injectors and combustion chamber swirlers using selective laser melting for engines including the Arrano and Ardiden 3. Safran has also extended additive manufacturing into actuation and landing gear systems, working with Airbus and SLM Solutions to design and test 3D printed nose landing gear and hydraulic system components.

The first one thousand 3D printed parts from the Safran Additive Manufacturing Campus were delivered to Safran Helicopter Engines in 2023. The campus has been delivering thousands of parts oer year since.