11-01-2016: GE Aviation has taken a historic step toward adopting AM in aircraft engine manufacturing

Company announced the results of testing a 35% additive-manufactured demonstrator engine designed to validate 12 3D-printed parts in its Advanced Turboprop (ATP) engine

On November 1, 2016, GE Aviation completed testing of a demonstrator engine that marked a milestone in turbine development using 3D printing technology. The project focused on the Advanced Turboprop (ATP) engine, designed specifically for the new single-engine Cessna Denali aircraft. The ATP’s construction included 35% 3D-printed components, significantly reducing the engine’s weight by 5% and improving fuel efficiency by 1%.

The ATP engine was based on the earlier CT7 model, which was adapted using 3D printing into what is known as the “a-CT7” — a demonstration engine for testing. During this process, GE replaced as many as 855 conventionally manufactured parts with only 12 printed components, including essential elements such as bearing housings, heat exchangers, combustion chamber, and structural frames. This approach made the engine lighter and more wear-resistant by eliminating the need for multiple connections like bolts and welds, which can reduce engine efficiency.

The ATP project was led by the same engineering team responsible for developing the fuel nozzle in the LEAP engine, one of the first major 3D-printed components in aviation. The work on the a-CT7 proceeded at an exceptionally rapid pace — just 18 months from design to testing, with some parts, like the combustion chamber, printed in only two days. The 3D printing technology also allowed testing to be conducted six months ahead of schedule.

Following the ATP’s success, GE continued using 3D printing in subsequent engine projects, such as LEAP and GE9X, which were introduced to both the commercial and military markets. The LEAP engines, used in Airbus A320neo and Boeing 737 MAX aircraft, feature 3D-printed fuel nozzles that contribute to a 15% fuel saving and improved durability compared to previous models (e.g., CFM56). Each GE9X engine includes over 300 3D-printed parts, enhancing performance and reducing weight by 10% compared to earlier generations.

Another example is the Catalyst engine, developed based on the experience gained from ATP, which includes 30% additively manufactured components, shortening production time and increasing fuel efficiency. Furthermore, Catalyst is one of the first commercial engines entirely designed using additive manufacturing methods.

Source: www.geaerospace.com