“There’s no part that just comes off a printer and goes straight into the engine,” Gatlin says. The Northern Italian town of Cameri could be easily mistaken for a quiet farming commune. GE’s new LEAP and GE9x jet engines are among the most ambitious programs in the company’s history. Offering a suite of products to help unlock the full potential of additive manufacturing. Several parts benefit from the use of custom supports. “When the GEnx program kicked off, they just hogged the brackets out of a big block of metal,” Martinello says. That’s a big deal given that fuel accounts for about 19 percent of an airline’s operating costs. Avio Aero started exploring 3D printing more than a decade ago. “It’s a highly collaborative process,” Martinello says. For the last four years GE has been manufacturing 3D printed fuel nozzles for the A320's jet engine. Above: The 3D printed nozzle combined all 20 parts into a single unit, but it also weighed 25 percent less. Cameri is the home of the only final assembly plant outside the United States for Lockheed Martin’s F-35B Joint Strike Fighter, a stealthy jet that can take off and land vertically. “When you are printing it, it’s hard to tell whether it’s one part or four parts, but when you cut them off the plate, they separate and you have an aircraft’s worth of brackets in one build.”. It’s about understanding what it can do, and how it can improve your designs.”, https://www.facebook.com/GE/videos/10160864544500422/. Martinello knows this as well as anyone. Twenty parts were once machined together to construct part of the CFM Leap engine. Voices is a network for GE’s US supporters interested in the company’s impact in their communities and in issues that impact the company. GE Aviation acquired Avio Aero in 2013 and developed the GE9X engine for Boeing’s next-generation 777X jets. The group, based in the U.S. and also in Germany, would get together every day on a 7:30 a.m. conference call to track their progress and lay out their next steps. A culture of integrity, compliance, safety, and respect for human rights, while reducing our environmental footprint. Above: GE Aviation's Additive Technology Center in Cincinnati might easily be the world’s largest and most advanced 3D-printing and development center. “We want to have everything quantified and take variation out of the process,” Martinello says. Sixty other designs are being perfected, some reducing the number of parts … Back in Cincinnati, Gatlin, Martinello, Brandel and their colleagues are already working on their next projects. “This factory has helped us understand what the art of the possible is with additive manufacturing,” said David Joyce, president and CEO of GE Aviation. The engineers from ATC and Auburn spent the spring collaborating and comparing notes so that Auburn will be ready to start cranking out the brackets. Tune in or catch up on GE’s latest investor events and reports. It weighs 50 percent less than the metal alloys typically used in aviation. “The location was part of our strategy,” Abrate says. One of the team’s tasks early on was making sure that brackets coming out of the machines were of identical quality. Explore a timeline of GE technologies that have spurred transformation across the world. For example, they took a system designed to air out the smoke produced when the powerful lasers hit and melt the layers of powder into the desired shape, and gave it more power. Read on to see how. Creating the energy technologies of the future and improving the power networks that we depend on today. More than a third of the ATP engine’s parts will be crafted in 3D printers. Commercializing GE’s technology and IP to accelerate growth and achieve market differentiation. GE's dedicated team, leading technology, and global reach and capabilities help the world work more efficiently, reliably, and safely. If left untreated, smoke could deposit soot into the tiny pools of molten metal created by the lasers and alter the density of the part — but also disperse the laser beam and make it less sharp, like sun rays filtering through morning fog. Access GE’s recent and historic Annual Reports and accompanying materials. Transforming how industry solves its toughest challenges by bringing simplicity, speed and scale to digital transformation. Jet engine designers love this strong, heat-resistant wonder material, also known as TiAl. Image credit: Tomas Kellner for GE Reports. Also known as additive manufacturing, it has opened new paths for designers to create custom shapes that were previously too expensive or downright impossible to make. 3D printing and dozens of other new technologies used for the first time in a civilian turboprop engine allowed the team to combine 855 separate components into just 12, shave off more than 100 pounds in weight, improve fuel burn by as much as 20 percent, give it 10 percent more power and simplify maintenance. Offering a suite of products to help unlock the full potential of additive manufacturing. The size of a walnut, this wickedly complex metal part was previously made from 20 components. Running more experiments, he also learned that preheating the powder before printing removed much of the residual stress from the finished parts. GE’s LEAP engine with 3D printed parts helps rake in $31 B at Paris Air Show. Tune in or catch up on GE’s latest investor events and reports. At the time, word got out that GE Aviation had used TiAl blades inside the GEnx jet engine it was developing for Boeing’s Dreamliner. Voices is a network for GE’s US supporters interested in the company’s impact in their communities and in issues that impact the company. The engine in question is actually a 3D-printed model, designed by GE. June 26, 2017 Staff. GE also opened additive manufacturing labs in the U.S. focusing on the technology. Explore the latest stories, news, downloads, and press tools. They’ve identified more than 100 components that could be printed. Discover how our people & technology are solving global issues, improving lives, and changing industries. GE plans to produce 100,000 3D-printed components for the next-generation GE9X and Leap models Courtesy of GE Aviation Transforming how industry solves its toughest challenges by bringing simplicity, speed and scale to digital transformation. More than a third of the ATP is 3D-printed from advanced alloys. GE's dedicated team, leading technology, and global reach and capabilities help the world work more efficiently, reliably, and safely. Additive ManufacturingAerospace3D printingGE. Access important shareholder information. We connect capital to infrastructure and deliver innovative financial solutions that help make the world work better. That's the step that GE Aviation took when it recently fired up a simple jet engine made entirely of 3D-printed parts in a test stand normally reserved for commercial jet power plants. But  TiAl is also very brittle. Engineers working on the ATP are planning to run it for the first time in a special test cell in Prague, Czech Republic, later this year. Last year, a team of engineers at GE Aviation’s Additive Technology Center built an almost entirely 3D printed miniature jet engine — a backpack-size powerhouse that hits 33,000 rotations per minute. “But as soon as you have to print thousands of copies of the same part consistently, you are in a territory that’s both similar to traditional manufacturing, but also more complex than anything that we’ve had before.”. He says this is especially important in aviation because of tight FAA regulations due to the importance of safety and quality in air travel. A model of a 2-spool high bypass turbofan. “It looks like one of those woodblock puzzles, where all the pieces fit together,” Gatlin says. A GEnx engine on a test stand in Peebles, Ohio. According to GE … “At that point, we knew what to do,” Abrate says. Working in a parallel track, a team of engineers was readying the Concept Laser machine for mass production. Learn how we’re delivering on our priorities. As a result, more than a third of the engine is 3D-printed. Got broken things that need a little TLC? We wanted to promote 3D printing to potential customers and they were all coming here.”, That gamble required access to 3D printers, which Avio Aero obtained by partnering with ProtoCast, an Italian 3D-printing pioneer based in a workshop a short drive from Cameri. I think that breeds a certain amount of excitement, a certain amount of energy, and requires a certain culture.” Image credit: GE Aviation. Answers to popular and relevant inquiries. “We ran a lot of experiments to get the job right.” Learn more about our culture, businesses, and life at GE. We’re deeply proud of GE employees around the world rising to the challenge. Together with our customers, we’re proving that no one is ever limited to only affordable, reliable, or sustainable energy. The printed plane engine has arrived. When it comes to flying, he says, every ounce counts. The beam “grows” the blades, which are 40 centimeters long, by welding together thin layers of titanium aluminide powder, one after another. “By the time you had the finished product, you cut away more than half of it.” The team realized that by 3D-printing the part, they would be able to reduce as much as 90 percent of the waste. “Fundamental engineering principles still apply. Commercializing GE’s technology and IP to accelerate growth and achieve market differentiation. 3D printed aircraft component . Until 3D printing came along, the only way to shape it involved molding, a somewhat dirty process that requires expensive tools. The two … Access the latest press releases, media contacts, and press tools. “In the design of jet engines, complexity used to be expensive," Ehteshami says. Image credit: GE Aviation. Access the latest press releases, media contacts, and press tools. We connect capital to infrastructure and deliver innovative financial solutions that help make the world work better. Of those, one-third are new products like the Catalyst engine, but the rest involve redesigning existing parts like the bracket — a huge new market for additive manufacturing. Explore a timeline of GE technologies that have spurred transformation across the world. Our technology, global network, and exceptional team is fueled by a mission—building a world that works. “Air flow is pretty critical in terms of getting parts with good internal and external quality,” Brandel says. “This is true if you have to print just one part,” he says. At GE, we rise to the challenge of building a world that works. “It took time for it to sink in, before we realized that this is exactly what additive can be used for, to demonstrate its speed and low cost.”. By embracing diverse teams and perspectives, we are better equipped to build a world that works. Explore a career with us. Starting with rockets, our Stargate factory vertically integrates robotics, software, and patented 3D printing technologies to digitize manufacturing. But the project was only half done. The technology's potential is enormous, but GE engineer Peter Martinello offers a dose of perspective. We build intelligent devices, data analytics, applications and services to enable healthcare practitioners to deliver care more efficiently and with better outcomes. GE has received orders for 1,658 LEAP and other engines, which can each include up to 19 3D printed fuel nozzles. 3D printing is still so new that Martinello, who is 37, is often learning on the job. Mohammad Ehteshami, who launched GE Additive, expects the industry to grow from $7 billion today to $80 billion in a decade. Our technology, global network, and exceptional team is fueled by a mission—building a world that works. First, members of the Additive Global Management team, who decide what to print, had to agree on whether they even wanted to make the part. Creating the energy technologies of the future and improving the power networks that we depend on today. The part (seen here) was a sensor housing for the jet engine. Read the latest GE financial news releases and stories. It already was a single piece of metal, and because it’s already inside a working engine, the GEnx first flew in 2010, the designers had to stay close to drawings approved by the FAA. Learn about governance at GE, including the latest Proxy Statement and information about the GE Board of Directors. “I’ve been doing this for three years now, but I still have to take a step back and remind myself what it is we are trying to do and why,” he says. The company has completed testing of a demonstrator engine on which the ATP will be based that is made from more than 35 percent 3D-printed parts. Explore GE’s recent and historic SEC filings. In 2016, GE  took a majority stake in Arcam and launched GE Additive, a new business focusing on additive manufacturing technologies like 3D printing. As a senior engineer for additive design at GE Aviation’s Additive Technology Center (ATC) in Cincinnati, in 2016 he helped bring to mass production a 3D-printed fuel nozzle that efficiently sprays fuel inside the LEAP jet engine. GENERAL ELECTRIC, 763, DC TRACTION MOTOR, LOCOMOTIVE TRACTON MOTOR. Now there's only one piece—and it's five times stronger. “We were being charged a significant amount for these parts,” Gatlin says. Ignition, Combustion and Detonation engineering . As a senior engineer for additive design at GE Aviation’s Additive Technology Center (ATC) in Cincinnati, in 2016 he helped bring to mass production a 3D-printed fuel nozzle that efficiently sprays fuel inside the LEAP jet engine. Explore the latest stories, news, downloads, and press tools. What if a fix was as simple as whipping up your own 3D printed parts? Read the latest GE financial news releases and stories. “They were already convinced,” Abrate says. “I like to get my hands dirty and get to understand the inner working of the machine, rather than just churning out hardware,” he says. But early runs with ProtoCast’s laser-powered printers failed. Every two weeks, engineers pitch their ideas to this diverse body, which includes employees from GE Aviation’s supply chain, engineering and engine product lines. But the part for the GEnx, a simple bracket the size of a human rib that holds open the engine cover during servicing, had few of these qualities. GE has been working on the engine for the last three years. Aircraft engineering . They selected Concept Laser’s M2 printer, a fast, midsize machine that uses a pair of lasers to print four brackets at a time. Accomplished leaders building GE’s legacy. The size of a walnut, this … We’re continuing to do all we can to support our customers and employees during this unprecedented time. The list includes printing parameters, but also heat treatment and inspection steps. When Avio Aero showed GE what it was doing with the wonder metal, the American company quickly grasped the magnitude of the breakthrough. GE Aviation was developing its own 3D printing program near its headquarters in Cincinnati. We’re continuing to do all we can to support our customers and employees during this unprecedented time. “It was really a garage,” Abrate recalls. Discover how our people & technology are solving global issues, improving lives, and changing industries. The 3D printing factory, which looks like a blue and gray jewel box of steel and glass from the outside, holds 20 black, wardrobe-sized 3D printers, made by Arcam. “We just had to machine some bolt holes and some clevis pins and we were done,” he says. “If it has only 50 percent of the weight of the nickel alloys you’ve got to believe this is here to stay.”, GE cast the blades in a foundry, but Avio Aero, which wanted to go after the emerging TiAl market, bet on 3D printing. Additive manufacturing is still a young industry, albeit one going through a growth spurt. “For us to step up and bet the engine on this technology is a big deal,” Robert Schafrik, then GE Aviation’s materials and process engineering general manager, told FlightGlobal. Image credit: Adam Senatori for GE Reports Last year, GE Additive and GE Aviation proposed a collaborative metal additive manufacturing program with the U.S. Air Force to accelerate the adoption of AM for spare parts. That created some hand-wringing. Read More Explore GE’s recent and historic SEC filings. GE Aviation Auburn currently operates more than 40 metal 3D printers for the purpose of part production. GE Aviation is a world-leading provider of aircraft engines, systems and avionics. A culture of integrity, compliance, safety, and respect for human rights, while reducing our environmental footprint. “The Lockheed plant made the town become very visible among aerospace companies. “Minor tweaks here and there are OK in the development phase, but when you get into production, everything has to be locked down," says Danny Brandel, a lead manufacturing engineer at the ATC and a member of the team. He says that when GE acquired Avio Aero in 2013, “it was really fortunate because everything accelerated after that.”. It’s just a new tool that you have at your disposal. GE Aviation plans to begin mass-producing the GEnx parts this month at its factory in Auburn, Alabama. Over the last 10 months, they've developed a new process to mass-print a much larger part for a version of the GEnx jet engine that powers the latest generation of Boeing 747s. At GE, we rise to the challenge of building a world that works. To do so, the team also had to “production-proof” the new line of printers for the part. This is the first time GE has designed a mass-production process for a line of its own printers made by Concept Laser, a German engineering company it acquired in 2016. The FAA recently cleared the first 3D printed part in a commercial jet engine from GE. “These are big blades,” says Giorgio Abrate, general manager for engineering at Avio Aero. By then, Avio Aero bought ProtoCast and signed an exclusive agreement with Arcam to acquire a set number of the modified machines. By embracing diverse teams and perspectives, we are better equipped to build a world that works. The team also implemented small design tweaks that reduced the bracket’s weight by 10 percent. “We could see how difficult it was to make these blades,” Abrate says. We build intelligent devices, data analytics, applications and services to enable healthcare practitioners to deliver care more efficiently and with better outcomes. GE Additive Print Services Center is a full-scale, certified AS9100/ISO9001 additive printing and post-processing facility. This is an engineer’s dream." Learn how we’re delivering on our priorities. Itemlive.com GE Sends First T408 to Navy 3D Printing Industry Boeing 777X: GE9X engines with 300 3D printed parts powers largest twin-engine jetliner in first flight There are also nine manufacturing engineers, who keep improving the production process. GE's innovation engine where ideas become reality to create a better world and deliver differentiated tech across the company's industrial portfolio. Call it the little engine that could. And just across from the plant’s runway stands another futuristic manufacturing gem: Avio Aero’s 3D-printing factory making sleek turbine blades for the GE9X, the world’s largest jet engine, which took its maiden flight last week. Top: Brandel (left) and Martinello (right) hold in their hands 3D-printed brackets for the GEnx-2B engine. what the prefix means in different engine families of GE waukesha.ATGL,APG,VHP,VGF,VSG,275 GL. The designers reduced 855 separate parts down to just 12. The fist-sized T25 housing for a compressor inlet temperature sensor was fabricated by GE Aviation and will be retrofitted to over 400 GE90-94B jet engines on Boeing 777 aircraft. “We called it ‘the submarine’ because it was so narrow you couldn’t walk past the people working with the machines.”. The Blade Runners: This Factory Is 3D Printing ... - GE.com That’s when a group of designers working at the ATC came up with a clever solution: fitting all the parts like interlocking fingers onto a single “build plate” the size of an average computer screen. Read the results of the 2020 GE Global Innovation Barometer, titled “Pride and Protectionism: A Quest for Innovation Agency.”. “The reason we did this project was because it represented several firsts for us,” says Eric Gatlin, a general manager for GE Aviation’s additive integrated product team. GE Aviation is a world-leading provider of aircraft engines, systems and avionics. GE engineers 3D print mini jet engine, then power it to 33,000 RPMs Printing your own mechanical parts or toys is really easy, not to mention fun, using a 3-D printer. We’re deeply proud of GE employees around the world rising to the challenge. “A lot of the things we do here, we are doing for the very first time. Together with our customers, we’re proving that no one is ever limited to only affordable, reliable, or sustainable energy. The blades were cracking when Abrate and the team tried to separate them from the platform on which they were printed. But Martinello and his colleagues have just taken that feat to a new level. But additive allows you to get sophisticated and reduces costs at the same time. Contact information for general inquiries and feedback. The first GE jet engine to actually take flight while using a 3-D-printed part is the GE90. The new approach would not only allow GE to produce the part in-house, but also to reduce supplier expenses. The goal is to help organizations adopt additive manufacturing technology faster by offering the ability to take parts from an idea to production. “When the project first came to us, we said, ‘This is an oddball, this is an outlier,'” Gatlin says. “It’s not hard to walk into this building every morning and go to work,” says Eric Gatlin, a general manager for GE Aviation focusing on additive manufacturing. They started by focusing on individual machines, but in the future, they will feed the data into the cloud, monitor the parameters across a whole fleet of printers and look for patterns that will allow them to spot potential problems early. The 3D printed fuel nozzle inside the GE9X was 3D printed by Morris Technologies, which was acquired by GE in 2012. The GE90 is one of the world’s most powerful jet engines. Electric motors & generators engineering . It was developing a 3D printed fuel nozzle for a new jet engine called the LEAP and working with Greg Morris, the founder of Morris Technologies and another leading light in the additive movement. Answers to popular and relevant inquiries. The submarine, however, had a secret weapon: a powerful Arcam printer that print parts from TiAl powder. Read the results of the 2020 GE Global Innovation Barometer, titled “Pride and Protectionism: A Quest for Innovation Agency.”. But take a short ride through the rolling fields of the fertile Po Valley that surround it and you’ll discover a startling contrast. Getting the part ready for printing was another riddle. Our proprietary process optimizes every aspect of aerospace development and enables faster, more frequent, and lower cost access to space. For example, I think Rolls-Royce makes the best-looking fans, so there's some resemblance there... By the way, this model was featured on SolidSmack. FORECAST 3D has been providing 3D printing & custom manufacturing to our customers in a variety of industries ranging from healthcare to aerospace, consumer goods to design. The blades from Cameri are already working inside the first GE9X engines, which GE started testing last year. 3D printing has rightfully gotten a lot of buzz because of the marvels it can do. Explore a career with us. Learn about governance at GE, including the latest Proxy Statement and information about the GE Board of Directors. “But we had positive experiences with 3D printing on a military project.”, The company decided to take advantage of the nearby Joint Strike Fighter assembly plant and set up its additive manufacturing shop nearby. Boeing 777X: GE9X engines with 300 3D printed parts powers largest twin-engine jetliner in first flight GE Aviation has announced that American multinational aerospace giant Boeing has … Says one of the engineers, Dario Mantegazza, about 3D printing: “You have the ultimate manufacturing freedom.”. GE now prints 600 of them per week as a single piece. The first GEnx engines used brackets made with traditional methods such as milling. A single machine can simultaneously print six turbine blades directly from a computer file by using a powerful 3-kilowatt electron beam. But in order to make the approach economical, they had to print four brackets at a time. To move faster, the team decided to print the bracket from a cobalt-chrome alloy — rather than the original nickel-based superalloy, Inconel 625 — because the FAA already certified it for use inside engines. This week GE released this great GIF of its 1,300-horsepower advanced turboprop (ATP) engine in which more than one-third of … The 3D-printed blades spin inside the engine at 2,500 times per minute and face searing heat and titanic forces. For example, they are working on significant cost- and weight-reduction projects across their other engine lines like the LEAP, the GE9X engine for Boeing’s new 777X widebody jet, and military programs. To keep an eye on the conditions inside the machines, the engineers installed sensors and high-resolution cameras to monitor the power and stability of the laser, the oxygen levels in the printing chamber and other factors. The aluminium manifold inlet, 3D printed on a Concept Laser X LINE 2000R from GE Additive, took five days to complete. Access important shareholder information. GE Aviation plans to mass-produce them on Concept Laser 3D printers. GE's innovation engine where ideas become reality to create a better world and deliver differentiated tech across the company's industrial portfolio. A few weeks ago General Electric announced that the FAA (U.S. Federal Aviation Administration) cleared their first 3D printed part to fly. The company is already using individual 3D-printed fuel nozzles and other parts in its jet engines and gas turbines. Contact information for general inquiries and feedback. These and other new materials and technologies will help make the engine 10 percent more fuel-efficient than its predecessor, the GE90. “It’s our first program we certified on a Concept Laser machine, and it’s also the first project we’ve taken from design to production in less than 10 months.”. Fortunately for GE, the company now owns two of the largest metal 3D printer … For more than 25 years, our focus has been on bringing your ideas to life faster than you thought The Cameri plant employs eight specialized hourly workers feeding the machines with powder, removing and cleaning the printed parts, and doing maintenance. ” Abrate says and the team also had to machine some bolt holes and some clevis pins and were. Engine in question is actually a 3D-printed model, designed by GE in 2012 was making sure machines. Gotten a lot of the engine, ” Martinello says and reduces costs at the same time highly... Approach economical, they had to machine some bolt holes and some clevis pins and were... Quest for Innovation Agency. ”, VGF, VSG,275 GL near its headquarters in Cincinnati, systems and.... Avio Aero bought ProtoCast and signed an exclusive agreement with Arcam to tweak the machine ’ s history to,... Inlet, 3D printed on a test stand in Peebles, Ohio work efficiently. 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