Liebherr-Aerospace, based in Toulouse, France, has achieved a new milestone in additive manufacturing with the approval of a titanium flex shaft for Airbus. This complex component will now enter serial production following approval by Airbus and the European Union Aviation Safety Agency (EASA).

Liebherr's 3D Printed Flex Shaft Now EASA-Approved

The lightweight flex shaft, 3D printed with titanium. (Image Credit: Liebherr-Aerospace)

Utilizing Laser Beam Powder Bed Fusion (PBF-LB) technology, Liebherr was able to consolidate an assembly of seven conventionally manufactured parts into a single additively manufactured component. This redesign enhances reliability and significantly reduces the component’s weight.

The flex shaft, part of the Airbus A350 high lift system, will be integrated into the active differential gearbox of the flap system. Its function is to transmit rotary movement to a position sensor, compensating for angle and axis misalignment between the gearbox and the sensor.

Liebherr-Aerospace has a history of using additive manufacturing for aerospace applications. In 2019, they began serial production of an additively manufactured proximity sensor bracket for the A350 nose landing gear. This bracket was the first Airbus system part qualified for titanium additive manufacturing.

The flex shaft, with its higher degree of complexity, marks a significant advancement in Liebherr’s additive manufacturing capabilities, enabling more highly integrated aerospace systems.