Charles R. Goulding and Preeti Sulibhavi discover how COMAC’s innovative use of large-scale 3D printing technology positions it to disrupt the Boeing-Airbus stronghold and redefine aerospace manufacturing.
China’s rapid advancements in large-scale 3D printing technology have remained relatively under the radar, yet they play a pivotal role in the nation’s aerospace ambitions. The Commercial Aircraft Corporation of China (COMAC), at the forefront of this movement, is leveraging additive manufacturing to develop indigenous aircraft like the C919, aiming to challenge the longstanding duopoly of Boeing and Airbus.
COMAC’s Early Adoption of 3D Printing
In the mid-2000s, COMAC began exploring additive manufacturing to enhance its aircraft development processes. By 2007, the company had initiated collaborations to integrate 3D printing into the production of aircraft components. This early adoption allowed COMAC to produce complex parts with reduced weight and increased structural integrity, essential for modern aviation demands.
One significant application has been the use of 3D printed titanium parts in the C919 aircraft. These components contribute to weight reduction and improved performance. Additionally, 3D printing facilitates rapid prototyping, enabling COMAC to iterate designs swiftly and efficiently.
Advancements in Large-Scale 3D Printing
China’s commitment to advancing large-scale 3D printing (LS3DP) is evident through its research and development efforts. Overcoming size constraints in additive manufacturing has been a focal point, with strategies aimed at fabricating large functional structures without compromising precision or material properties. These advancements are crucial for producing sizable aircraft components, such as fuselage sections and wing structures, integral to COMAC’s manufacturing capabilities.
Challenging the Boeing-Airbus Duopoly
COMAC’s emergence presents a formidable challenge to the Boeing-Airbus duopoly that has dominated the commercial aviation market for decades. Unlike previous attempts by other manufacturers, COMAC is not merely replicating existing aircraft models but is developing products tailored to China’s specific market needs. The C919, designed for the single-aisle market, directly competes with the Boeing 737 and Airbus A320 families. With China’s vast domestic market and growing demand for air travel, COMAC is well-positioned to serve its national carriers, reducing reliance on foreign aircraft.
Recent reports indicate that COMAC aims to expand its market presence beyond China. The company plans to have the C919 operating on routes to Southeast Asia by 2026, marking its first foray into international markets. Additionally, COMAC is seeking European certification for the C919, a move that could open doors to broader markets and further challenge the existing duopoly.
Leveraging 3D Printing for Competitive Advantage
COMAC’s strategic use of 3D printing technology offers several advantages in its quest to compete with established aerospace giants:
- Cost Efficiency: Additive manufacturing reduces material waste and lowers production costs, enabling COMAC to offer competitive pricing for its aircraft.
- Supply Chain Independence: By producing components in-house using 3D printing, COMAC decreases dependence on international suppliers, mitigating risks associated with global supply chain disruptions.
- Customization and Innovation: 3D printing allows for the creation of customized components tailored to specific airline requirements, fostering innovation in aircraft design and functionality.
The integration of 3D printed parts in the C919 has already demonstrated success. Several non-flight-critical components have been produced using additive manufacturing, contributing to the aircraft’s overall efficiency and performance.
Top-ranking Chinese 3D printing companies include:
Future Prospects and Challenges
While COMAC has made significant strides, challenges remain in its pursuit to rival Boeing and Airbus on a global scale. Achieving international certifications, establishing a global maintenance and support network, and ensuring consistent quality and safety standards are critical hurdles that COMAC must overcome.
Nonetheless, China’s commitment to advancing its aerospace industry, coupled with strategic investments in technologies like 3D printing, positions COMAC as a formidable contender in the commercial aviation sector. As the company continues to innovate and expand its market presence, the dynamics of the global aerospace industry may witness a significant shift in the coming years.
The Research & Development Tax Credit
The now permanent Research and Development (R&D) Tax Credit is available for companies developing new or improved products, processes and/or software.
3D printing can help boost a company’s R&D Tax Credits. Wages for technical employees creating, testing and revising 3D printed prototypes are typically eligible expenses toward the R&D Tax Credit. Similarly, when used as a method of improving a process, time spent integrating 3D printing hardware and software can also be an eligible R&D expense. Lastly, when used for modeling and preproduction, the costs of filaments consumed during the development process may also be recovered.
Whether it is used for creating and testing prototypes or for final production, 3D printing is a great indicator that R&D Credit-eligible activities are taking place. Companies implementing this technology at any point should consider taking advantage of R&D Tax Credits.
Conclusion
COMAC’s utilization of large-scale 3D printing technology underscores China’s broader strategy to enhance its manufacturing capabilities and reduce dependence on foreign technology. By leveraging these advancements, COMAC is not only developing competitive aircraft but also laying the foundation for a more self-reliant and innovative aerospace industry.
