Charles R. Goulding and Andressa Bonafe spotlight Safran and how it is leveraging 3D printing and cutting-edge manufacturing to lead Europe’s aerospace and defense transformation, amid a surge in defense spending.
Established in France in 1896, Safran has grown into one of the most longstanding and influential companies in the aerospace industry, with a heritage rooted in early aircraft engine development. What began as a pioneering effort in aviation has evolved into a leading international high-technology group operating across the aerospace, defense, and space sectors.
Today, Safran employs more than 100,000 people at 276 sites in 27 countries and reported €27.3 billion in revenue in 2024. The company holds global leadership positions in several key markets, including as the top supplier of engines for single-aisle commercial jets (through CFM International, a joint venture with GE), helicopter turbine engines, and landing gear systems. With a strong focus on research and innovation, Safran is committed to making air transport safer, more sustainable, and more accessible, paving the way for the next generation of aerospace solutions.
A New Era for European Defense
Despite its longstanding tradition and deep-rooted presence in global aerospace, Safran is now operating in an unprecedented defense environment. The ongoing escalation of geopolitical tensions have prompted a dramatic shift in Europe’s defense posture. At the heart of this transformation is the €840 billion “ReArm Europe” plan, an ambitious effort to enhance military readiness, modernize aging fleets, and reinforce regional security. Countries such as Germany have enacted sweeping military budgets at a pace and scale unseen in the post-war era, signaling a break from decades of restrained defense investment.
This surge in funding is reshaping the competitive landscape. Key players like Airbus, BAE Systems, Dassault Aviation, and Rheinmetall are scaling up production and development efforts to meet growing demand for next-generation systems, from fighter aircraft to advanced missile platforms. Many governments are now prioritizing domestic and European contractors for new contracts, creating both opportunities and heightened competition.
In this context, additive manufacturing has emerged as a strategic enabler. It offers the ability to produce lightweight, complex components with shorter lead times and reduced waste, an advantage that aligns well with Europe’s ambitions for both efficiency and innovation. With European defense budgets expanding and governments seeking both technological edge and strategic resilience, additive manufacturing is expected to play an even more central role in the modernization of Europe’s defense infrastructure.
3D Printing at Safran
Safran has been increasingly adopting 3D printing technologies to improve the performance and sustainability of its products. According to CEO, Olivier Andriès, the company views additive manufacturing as a key enabler of lighter, more efficient designs that support the aerospace industry’s environmental goals. He stated that, in the long term, up to a quarter of the components in some of Safran’s engines could be produced using this process.
This vision is supported by the work of Safran Engineering Services, which applies both metal and polymer additive manufacturing to develop prototypes, demonstrators, and production parts. Their approach includes material characterization, topology optimization, and supplier coordination, allowing Safran to reduce part weight by up to 25% and consolidate multiple components into single, more efficient structures. These efforts not only streamline production and improve product performance but also shorten development cycles and contribute directly to the group’s decarbonization strategy.
Safran Additive Manufacturing Campus
To consolidate its expertise in advanced aerospace manufacturing, Safran inaugurated the Safran Additive Manufacturing Campus in October 2022. Located in Le Haillan, near Bordeaux in southwest France, the 12,500-square-meter facility brings together all stages of additive manufacturing, from research and development to engineering and production. Designed as a center of excellence, the campus integrates cutting-edge technologies and digital production tools to support the entire Safran Group.
The site is equipped with up to 50 industrial 3D printers capable of working with a range of materials, including titanium, aluminum, nickel-based alloys, and polymers. These machines produce critical aircraft and engine components such as vanes, structures, and cases. In 2022, more than 100 highly-qualified engineers, scientists, and technicians were employed at the site, with plans to scale up to 200 personnel. The campus is also home to a training center and partners with engineering schools to cultivate specialized expertise in AM. As a low-carbon facility powered by electricity and waste heat recovery, the campus reflects Safran’s broader commitment to sustainability and innovation. By 2023, the site aimed to double its 2022 output of 4,000 parts, some of which are already in use by Safran Helicopter Engines.
Nose Landing Gear Component for Business Jet
One notable example of Safran’s use of additive manufacturing was the development of a titanium nose landing gear component for a business jet, created in collaboration with SLM Solutions in 2021. Traditionally produced through forging, a process that can be time-consuming and limited in design flexibility, this component was instead fabricated using metal 3D printing. The result was a complex part measuring over 80 centimeters in height, produced significantly faster and with a 15% reduction in weight. This project demonstrated not only the feasibility of printing large, load-bearing aerospace components but also the potential for additive manufacturing to streamline production timelines and improve overall performance in critical systems.
RISE Open-Rotor Jet Engine Project
One of Safran’s most ambitious ventures in additive manufacturing is its collaboration with GE through the CFM International joint venture to develop the RISE (Revolutionary Innovation for Sustainable Engines) program. As part of its long-term strategy to achieve net-zero emissions in aviation, Safran, through its CFM International joint venture with GE Aerospace, is developing the RISE (Revolutionary Innovation for Sustainable Engines) program. Unveiled in 2021, the project aims to deliver a new open-rotor jet engine that reduces fuel consumption and CO₂ emissions by at least 20% compared to current commercial engines. The core of this innovation lies in a single-stage open-fan design, which allows a significantly higher bypass ratio than traditional engines, coupled with a lightweight, compact core optimized for thermal efficiency and compatibility with next-generation fuels such as 100% sustainable aviation fuel (SAF) and hydrogen. Key breakthroughs also include the use of carbon-fiber composite blades and advanced supercomputing to refine aerodynamics and noise control—overcoming historical challenges associated with open-rotor configurations.
Although specific 3D printed components have not yet been disclosed, it is highly likely that additive manufacturing will play a central role in the RISE program, given GE and Safran’s extensive track record with the technology in previous engine platforms. The LEAP engine, also developed by CFM, featured 19 3D printed fuel nozzles per unit—each 25% lighter and five times more durable than conventional parts—while the GE9X engine incorporated over 300 printed components. Building on this foundation, the RISE program is expected to use 3D printing to enable complex turbomachinery geometries, reduce part counts, and accelerate prototyping cycles, helping Safran and GE meet ambitious environmental and performance targets through advanced manufacturing.
Safran’s example reflects a broader trend within the aerospace sector, where 3D printing is being widely embraced for its potential to reduce costs, speed up production timelines, and allow for more customized manufacturing solutions. Companies based in the United States that are leveraging additive manufacturing may also benefit from the R&D tax credit opportunities outlined below.
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 can be included as a percentage of eligible time spent for the R&D Tax Credit. Similarly, when used as a method of improving a process, time spent integrating 3D printing hardware and software counts as an eligible activity. 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
Safran’s sustained investment in additive manufacturing underscores its strategic commitment to innovation, efficiency, and environmental responsibility in aerospace. From its dedicated AM campus in France to pioneering applications in aircraft components and next-generation engine programs, the company is positioning itself at the forefront of a technological transformation that is reshaping the industry. While the full scope of 3D printing’s role in future programs like RISE remains to be seen, Safran’s track record strongly suggests that additive manufacturing will be a cornerstone of its efforts to meet the demands of a more sustainable and agile aviation future.
