Saab has collaborated with Divergent Technologies to develop what the companies describe as the world’s first software-defined aircraft fuselage using additive manufacturing. The 5-meter-long structure comprises 26 unique printed parts and was produced without traditional tooling or fixturing. Instead, the project utilized Divergent’s manufacturing platform that combines industrial laser powder fusion 3D printing with robotic assembly.
The fuselage represents part of Saab’s broader initiative called “Software-Defined Hardware Manufacturing,” led by the company’s internal innovation unit, The Rainforest. “We are asking ourselves the question – In Gripen E customers get a platform where they can code mission-critical applications in the morning and fly them in the afternoon. How can we give them the same level of software flexibility, but for actual hardware?” said Axel Bååthe, Head of The Rainforest.
According to Saab, the additive manufacturing approach allows load-bearing structures to follow optimal load paths rather than traditional straight lines and right angles. The company states this method can reduce the number of parts in a fuselage by a factor of 100 compared to conventional riveted assemblies. The technology also enables integration of systems like wiring and thermal management directly within the printed structure.
The fuselage has completed structural proof-loading tests and is scheduled for flight testing in 2026. This project builds on Saab’s use of model-based engineering methods in developing its Gripen E fighter aircraft, which the company says pioneered digital twin technology in aerospace design and production. Saab’s goal is to achieve what it calls “CAD in The Morning, Fly in The Afternoon” manufacturing capability.
Source: saab.com
