AerospaceAerospace 3D Printing and Additive Manufacturing News

New 12,500 sm Safran Additive Manufacturing Campus is on track to open in 2021

It will host as many as 50 production 3D printers

Aerospace giant Safran is bringing all of its additive manufacturing activities under one roof at a new site called the Safran Additive Manufacturing Campus. Construction of this Factory of the Future began in March and is on track to host as many as 50 production-grade 3D printers working with metallic powder or other feedstock, melted by a laser beam or other means.

To an aerospace pioneer like Safran, this production revolution affords many advantages in terms of enabling new designs, greater flexibility, weight and material savings. Even for Safran, accesso to internal metal 3D printing capabilities also means a chance to break the monopoly and its dependency on forging and casting companies, with the ability to craft complex parts more affordably than by machining. As well as producing parts that would otherwise be impossible to make using conventional technologies.

Accelerating and optimizing to add value

Safran is now seeking to further exploit the potential of additive manufacturing, an area it has been working on for nearly 20 years. Today, AM technology has reached maturity and some firms are beginning to employ it to make production parts. But to accelerate the process, every step involved had to be brought under one roof, from design and development to engineering and fabrication.

This is what inspired the creation of the Safran Additive Manufacturing Campus, a dedicated new entity. “AM involves so much more than just 3D printing,” explains François-Xavier Foubert, Safran Additive Manufacturing Campus CEO. “A lot of the value it adds lies in design and finishing. To make a leap forward in production rates and competitiveness, we need to optimize the entire process and bring together functions previously housed in separate facilities.”

Safran Additive Manufacturing Campus
Safran’s booth at the Paris Air Show 2019 was full of 3D printed parts and components.

A modern, eco-friendly facility

The new campus is set to open its doors at Le Haillan, near the Safran Ceramics site. Covering some 12,500 square meters (135,000 sq ft) of floor space, it will house research, design, development, engineering and production activities, as well as support functions. The factory will have up to 50 3D printers capable of handling a range of materials (aluminum, titanium, nickel-based alloys and polymers) to make different parts (vanes, structures, cases, equipment, etc.).

“The digital dimension will also be omnipresent,” says François-Xavier Foubert, “because AM is based on an integrated digital production system, from design to fabrication.” Last but not least, the line will be classified as “low-carbon” and powered exclusively by electricity or waste heat recovery.

Ultimately, the campus plans to have some 200 employees working in an environment tailored to additive manufacturing. There are a number of positions to fill, in research and technology, production and many other areas. “AM calls for new know-how, notably in 3D printing line design and control,” stresses François-Xavier Foubert. “We’re going to set up a training facility to support upskilling of employees who join us, as well as those working in AM Group-wide. We’re also forging partnerships with engineering schools to train tomorrow’s specialists.”

Construction got underway mid-April and is scheduled to be completed by the end of the first quarter of 2021.

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Davide Sher

Since 2002, I have built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, I spent 12 years in the United States, where I received my Bachelor of Arts undergraduate degree. As a journalist covering the tech industry - especially the videogame industry - for over 10 years, I began covering the AM industry specifically in 2013, as blogger. In 2016 I co-founded London-based 3D Printing Business Media Ltd. (now 3dpbm) which operates in marketing, editorial, and market analysis & consultancy services for the additive manufacturing industry. 3dpbm publishes 3D Printing Business Directory, the largest global directory of companies related to 3DP, and leading news and insights websites 3D Printing Media Network and Replicatore. I am also a Senior Analyst for leading US-based firm SmarTech Analysis focusing on the additive manufacturing industry and relative vertical markets.

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