Charles R. Goulding and Preeti Sulibhavi explore how Boeing’s innovative use of 3D printing is driving the elimination of ‘Shadow’ factories, boosting production efficiency, and enhancing the aerospace giant’s operational agility.
Boeing’s strategic initiative to phase out “Shadow” factories—a term harking back to World War II when automotive plants were repurposed for aircraft production—underscores the company’s commitment to streamlining operations and returning to pre-pandemic production levels. In Boeing’s context, “Shadow” factories refer to facilities dedicated to repairing and reinspecting previously sold aircraft, activities that can encroach upon resources intended for new aircraft manufacturing. By the close of 2024, Boeing successfully reduced the number of aircraft in “Shadow” status from 225 to 115. Central to this achievement is the integration of 3D printing, or additive manufacturing (AM), which has revolutionized both production and Maintenance, Repair, and Overhaul (MRO) processes.
Boeing’s Implementation of 3D Printing in Aircraft Production
Boeing has been at the forefront of adopting 3D printing technologies to enhance manufacturing efficiency and component performance. The company utilizes 3D printing to produce various components across its aircraft models, leading to weight reduction, improved fuel efficiency, and streamlined supply chains.
One notable example is the Boeing 787 Dreamliner. This aircraft incorporates numerous 3D printed parts, including environmental control ducting and engine components. The use of additive manufacturing in the 787 has contributed to a lighter airframe, enhancing fuel efficiency and reducing operational costs.
Another significant application is found in the Boeing 777X program. Boeing, in collaboration with Norsk Titanium, has employed 3D printing to produce titanium structural components for the 777X. These 3D printed titanium parts not only reduce weight but also decrease material waste and production time, exemplifying the benefits of additive manufacturing in large-scale aircraft production.
3D Printing in the Maintenance, Repair, and Overhaul (MRO) Industry
The MRO sector has embraced 3D printing to enhance operational efficiency and reduce aircraft downtime. Additive manufacturing enables on-demand production of spare parts, customization of components, and refurbishment of damaged parts, thereby streamlining maintenance processes.
For instance, StandardAero, a leading MRO provider, has integrated 3D printing into its repair services. The company utilizes additive manufacturing to produce complex engine components, allowing for rapid repairs and reducing the time aircraft spend out of service. This approach not only expedites the repair process but also extends the lifespan of existing components, offering a cost-effective solution for airlines.
Similarly, Lufthansa Technik has adopted 3D printing to fabricate cabin interior parts and tooling. By producing components such as seat parts and paneling in-house, Lufthansa Technik can offer customized solutions to airlines, reduce lead times, and maintain high standards of quality. This capability is particularly advantageous for older aircraft models where replacement parts may no longer be readily available.
The Role of 3D Printing in Eliminating “Shadow” Factories
The integration of 3D printing plays a pivotal role in Boeing’s strategy to eliminate “Shadow” factories. By adopting additive manufacturing, Boeing can produce replacement parts more efficiently, reducing the need for extensive repair and reinspection facilities. This shift allows the company to allocate more resources to new aircraft production, thereby enhancing overall operational efficiency.
Moreover, the use of Digital Twins—virtual replicas of physical components—facilitates predictive maintenance and quality control. By continuously monitoring the performance of aircraft parts, potential issues can be identified and addressed before they necessitate extensive repairs. This proactive approach minimizes the occurrence of defects and contributes to the goal of zero defects in manufacturing.
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
Boeing’s commitment to phasing out “Shadow” factories reflects a broader industry trend toward embracing advanced manufacturing technologies. The adoption of 3D printing has proven instrumental in enhancing production efficiency, reducing aircraft downtime, and improving overall quality control. As additive manufacturing continues to evolve, its role in both aircraft production and MRO operations is poised to expand, offering innovative solutions to longstanding challenges in the aerospace industry.
