Like all aircraft manufacturers, Airbus waged a constant battle with weight in all its new aircraft, and the A380 was no exception. Unlike anything before it, however, the sheer scale of the superjumbo meant that seemingly minor changes such as over-designed parts or inaccurate sensors could have massive downstream effects on weight. A 1 percent error in fuel calculation, for example, equated to the weight of 30 passengers.
Following the design changes implemented for QC/2 and the longer range requirements of Singapore Airlines and Qantas in 2000, the maximum takeoff weight inevitably ballooned to 1.23 million pounds, an increase of 35,000 pounds. The growth came from the added weight of the larger re-fanned engines, the addon wing weight to carry them, the additional fuel volume, changes to the control surfaces for improved takeoff performance, and structural enhancement for the added weight in the fuselage and undercarriage.
Weight adds weight, and very soon the situation threatened to get out of hand, creating a potential disaster for Airbus. Speaking in 2003, Charles Champion recalled the problems when he said that, “we had the idea to put the whole company in a crisis mode two years ago, and the pressure is still on.” Tiger Teams aggressively pursued a massive series of weight-reduction initiatives that, at one stage, numbered almost 50. Several structural modifications such as the use of composite ribs in the wings were implemented as a result, while others were studied for potential future use. Suppliers also were asked to cut weight, particularly in areas such as interior fittings, where they were tasked with taking out up to a massive 20 to 30 percent. The overall weight reduction target was set at an astonishing 22,000 pounds.