Aerostructures: solutions to support any programme

The Leonardo Aerostructures Business Unit is specialized in design, production and assembly of certified structural components in composite and traditional metallic materials for commercial & defense aircraft, crewed or uncrewed, with fixed or rotary wing.

It collaborates with main civil aircraft manufacturers in Europe (Airbus, ATR) and in the United States (Boeing) and also supplies components for military aircraft (F-35, Eurofighter Typhoon, C-27J), helicopters (AW249) and uncrewed platforms (EURODRONE) for the other Leonardo’s Divisions and Business Units.

The Aerostructures Business Unit studies and develops innovative materials and production processes through two Leonardo Labs: the Aerotech Campus of Pomigliano d'Arco and the Leonardo Lab of Grottaglie, interconnected with universities, polytechnics, research centres and partner companies to create a constantly evolving innovation ecosystem.

>1,900

ATR AIRCRAFT ORDERED BY ABOUT 200 AIRLINES IN 100 COUNTRIES

>2,700

FUSELAGES SECTIONS MANUFACTURED FOR THE AIRBUS A321 AND OVER 550 TAILS UNITS FOR THE AIRBUS A220

>1,300

FUSELAGES DELIVERED FOR THE BOEING 787 PROGRAMME

ATR

The ATR consortium – a joint venture owned equally by Leonardo and Airbus – is currently the world’s leading manufacturer of turboprop aircraft for regional transport. The ATR 42 and 72 are the best-selling aircraft in the market segment for aircraft with fewer than 90 seats. Leonardo is responsible for the entire Fuselage and Empennages, made of composite material, including systems, integration and testing of each component.

Boeing

Leonardo designs and produces 14% of the Boeing 787 Dreamliner, the world’s first airliner with majority of primary structure made of composite materials. The central and rear-central section of the fuselage and the carbon fibre horizontal stabiliser are made using Leonardo’s own patented plants, machinery and production processes. The ‘One Piece Barrel’ is the key innovative element in the monolithic structure of the Boeing 787: the manufacturing process enables integration of the maximum number of parts in a single component, reducing assembly work. Leonardo is also responsible for certification, production and assembly of all the moving surfaces of the wing and stabilisers of the Boeing 767.

Airbus

Leonardo and Airbus have worked together on the A321 programme since 1991, when the two companies signed an agreement for the design and production of the forward section of the aircraft fuselage, which is now also produced for the A321’s new configuration. Leonardo also produces the horizontal and vertical stabiliser for the Airbus A220, and is responsible for design, development, testing, qualification and production throughout the product’s entire lifecycle. From 2025, the company is responsible for the industrialization, fabrication and assembly of the Rear Fuselage of A220 to be produced in Nola site.

As a supplier to other Business Units and Divisions within the company, Leonardo Aerostructures produces complex metallic and composite parts for crewed and uncrewed platforms:

Prototype Design & Manufacturing Capabilities

The Aerostructures B.U. developed a large experience in supporting customers who need to design and manufacture complex
aerostructures for prototypes ensuring performance, quality and airworthiness in compliance with aerospace requirements.

The Business Unit developed prototype design & manufacturing capabilities achieving a compressed activities timeline (6-8 months from start to prototype delivery).