--- title: "Safran shows off large additive manufactured engine parts at Paris Air Show" url: https://www.voxelmatters.com/safran-shows-off-large-additive-manufactured-engine-part-at-paris-air-show/ date: 2025-06-17 modified: 2025-06-17 lang: en author: "Davide Sher" description: "At the 2025 Paris Air Show, engine manufacturer Safran presented a turbine rear frame made with additive manufacturing, marking a new stage in developing aircraft engine components. This 3-foot diameter..." categories: - "3D Printing Events" - "Aerospace AM" - "Aviation" - "Paris Air Show" tags: - "insights" image: https://www.voxelmatters.com/wp-content/uploads/2025/06/SAF2023_0432392-1-copia-640x360.jpg word_count: 692 --- # Safran shows off large additive manufactured engine parts at Paris Air Show At the [2025 Paris Air Show](https://www.voxelmatters.com/event/55th-international-paris-air-show/), engine manufacturer [Safran](https://www.voxelmatters.directory/company/safran/) presented a turbine rear frame made with additive manufacturing, marking a new stage in developing aircraft engine components. This 3-foot diameter part is the largest Safran has ever produced using the technology [and was created as part of the company’s RISE technology program](https://www.voxelmatters.com/safran-inaugurates-the-safran-additive-manufacturing-campus/). According to Delphine Dijoud, deputy vice president of engineering at Safran Aircraft Engines, the part is one-third lighter than a traditionally made equivalent. This weight reduction and the ability to produce more complex designs show the potential benefits of additive manufacturing in future engine designs. [![Learn about the Safran RISE program and its innovative approach to producing lightweight turbine rear frames for aircraft engines.](https://www.voxelmatters.com/wp-content/uploads/2025/06/safran-am.jpg)](https://www.voxelmatters.com/wp-content/uploads/2025/06/fabrication-additive-safran-eng-hd.pdf)Click to download the full-size PDF ## Improving production efficiency with additive manufacturing One of the key advantages of additive manufacturing for Safran is its ability to shorten the production cycle. The turbine rear frame that Safran showcased was produced in just three weeks. In comparison, traditional methods can take up to 18 months. Safran aims to reduce this cycle to one week or less eventually. In addition to faster production, the process allows changes to be made later in development, giving engineers more flexibility. Safran used a nickel superalloy to build the part, which is suitable for the high-temperature areas of an engine. Although additive manufacturing is not the cheapest way to melt metal, the process avoids the need for welds and enables more functional integration into single components. Safran uses Selective Laser Melting (SLM) technology to improve component design, reduce the weight of engine parts, and enhance overall fuel efficiency. The company highlights several important aspects of this approach in the infographic above. One is the use of additive manufacturing as an alternative to traditional casting methods, helping to strengthen the supply chain, as shown with the SP5 bearing bracket. It also illustrates the production of single-piece parts, such as the Case Monobloc for the RISE engine, eliminating the need for assembly and welding. Another feature is the potential to develop new form factors, allowing for more flexible and innovative engine architectures. Lastly, the infographic presents a clear example of weight reduction with a hydraulic unit, where the mass is reduced by 40 percent—from 4.4 kg to 2.6 kg—demonstrating how additive manufacturing can lead to more efficient and lighter components. ![Learn about the Safran RISE program and its innovative approach to producing lightweight turbine rear frames for aircraft engines.](https://www.voxelmatters.com/wp-content/uploads/2025/06/Safran_-2025-06-16-alle-22.18.55-copia.jpg)The RISE (Revolutionary Innovation for Sustainable Engines) program represents Safran’s strategic commitment to shaping the future of aviation propulsion. Launched in collaboration with General Electric, it aims to cut fuel consumption and CO₂ emissions by at least 20%. Additive Manufacturing plays a pivotal role in RISE, allowing engineers to rethink the very architecture of engine components. By leveraging AM, Safran can reduce part count, integrate new functionalities, and accelerate development cycles without compromising performance. ## Benefits and applications in Safran’s engines The additive manufacturing process helps improve the buy-to-fly ratio, which refers to the amount of material needed to produce a part. Traditional methods may require three to ten pounds of raw material to produce one pound of finished part. That ratio can be as low as 1.5 to 1 with additive manufacturing. This efficiency reduces material waste and the need for machining after printing, as the parts come out nearly ready for use. Safran is already using additive manufacturing to produce 14 types of engine parts, including components made from aluminum, titanium, and nickel alloys. The company plans to continue expanding the use of this technology in future engines developed under the RISE program, where 25 percent of the parts are expected to be made through additive manufacturing. According to François-Xavier Foubert, CEO of the Safran Additive Manufacturing Campus, future developments will allow the production of parts up to two meters in diameter. Improvements in equipment, such as machines with more powerful lasers that can melt thicker layers of metal powder, are expected to increase productivity further. Additive manufacturing is already an important part of Safran’s work in improving aircraft engines. The company's research facilities, including the Safran Tech site in Itteville, play a key role in testing and refining these new methods. As Safran continues to invest in this technology, it is expected to become a larger part of engine manufacturing strategies in the years ahead.