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Supply Chain Disruption: Russian Aviation Factory Adopts 3D Printing Technology to Produce Composite Components

September 24, 2025 Applications 34

Amidst sanctions, Russia's UZGA is using domestic 3D printing to slash production times for new aircraft components.

The Russian Ural Civil Aviation Plant (UZGA) is leveraging large-scale industrial-grade 3D printers from domestic sources to support the production of new aircraft models. These include the small multi-purpose aircraft "Baikal" LMS-90, the UTS-800 trainer, and the "Ladoga" regional airliner. Since 2024, the plant has installed two 3D printers capable of producing components up to 5 meters in length.

These equipment are currently being used to manufacture large-scale polymer composite tooling. UZGA stated that 3D printing technology has significantly shortened the production cycle. Taking the mold tooling required for vacuum-forming composite components as an example, the traditional process typically takes 10 to 12 weeks to complete, whereas with 3D printing technology, it only takes 2 to 3 weeks. Compared to other traditional manufacturing methods, this process also requires fewer personnel.

Internal view of the "Baikal" LMS-90 aircraft being fitted with 3D-printed components. Image source: Ural Civil Aviation Plant (UZGA).

The plant primarily relies on two additive manufacturing technologies:

The first is Fused Filament Fabrication (FFF) technology, which creates durable, large-scale structural components by extruding molten plastic reinforced with 30% carbon fiber. In-house testing at the plant has shown that tooling printed with this technology maintains high accuracy during the printing process.

The second is Fused Deposition Modeling (FDM) technology, currently used for manufacturing small structural parts for various aircraft models.

For a factory tasked with delivering new aircraft for the Russian aviation industry, adopting advanced manufacturing technologies is no longer just a cost-saving measure. Since Russia's initiation of the special military operation against Ukraine in 2022, the United States and the EU have restricted and banned the export of aircraft, parts, maintenance services, insurance, and technical assistance to Russia. This shift towards 3D printing reflects a current trend within Russia—using 3D printed components to circumvent sanctions.

An industrial-grade 3D printer of Russian origin used by the plant. Image source: Ural Civil Aviation Plant (UZGA).

Due to persistent supply chain disruptions and limited access to foreign technologies, Russian manufacturers are accelerating the development of domestic solutions. A recent study by NextMSC indicates that the market size of Russia's additive manufacturing industry reached approximately $481 million in 2023 and is projected to grow to around $19.3 billion by 2030.