Russian Aerospace Plant Turns to Large-Scale 3D Printing for Composite Parts

The Ural Civil Aviation Plant (UZGA), located in Yekaterinburg, Russia, has been utilizing some of Russia’s largest industrial 3D printers to support the production of new aircraft. These include the Baikal LMS-90, a small utility aircraft, the UTS-800 trainer, and the Ladoga regional plane. Since 2024, the plant has installed two printers that are capable of producing parts up to five meters in length.

These machines are being used to manufacture large-scale polymer composite tooling. According to UZGA, the technology has already drastically reduced production times. A forming tool for vacuum molding composite components, which would normally take 10 to 12 weeks to complete, can now be finished in just two to three weeks. The process also requires fewer personnel compared to other traditional methods.

An inside view of a Baikal LMS-90 being retrofitted with 3D printed parts. (Credit: UZGA)

The plant itself relies on two types of additive technology. The first is fused filament fabrication (FFF), which extrudes melted plastic reinforced with 30% carbon fiber to create durable and large-scale structures. Tests at the facility have shown that the printed tooling maintains high accuracy during prints. The second is fused deposition modeling (FDM), which is being used for smaller structural parts for each plane.