GE Aviation manufactures 3D printed parts specifically for GE Catalyst engines

China3D printingNet, May 2nd, at the end of 2018, Avio Aero, which was acquired by GE Aviation a few years ago, opened a second additive manufacturing plant in Brindisi, Italy. After a lot of structural work, the plant was transformed into a more modern one. Factory in order to use3D printingDirect metal laser melting (DMLM) technology for aerospace parts (also known as laser powder bed fusion, DMLS, selective laser melting, etc.).The plant is dedicated to GE Catalyst engine manufacturing3D printingParts, the engine will eventually be used in the light-weight Cessna Denali (Cessna Denali).

Cessna Denali will be the first aircraft powered by GE Catalyst. Picture: Textron Aviation)

This will be the world’s first turboprop engine, with nearly 30% of its internal parts made of metal3D printingManufactured, this technology makes it possible to reduce the total number of engine parts from as high as 855 to only 12.Ten of these parts will be carried out at Avio’s new plant in Brindisi3D printing, The plant employs 12 operators, process materials experts, production engineers and additive design teams, led by Dario Mantegazza, the head of additive manufacturing. As the factory adds more Concept Laser DMLM systems, the number of Catalyst components produced there may increase, which will also lead to an increase in the number of teams.

Mantegazza said: “The number of people in our team will double. When we reach full capacity, we expect to produce more than 300 engines per year.”
The Brindisi plant currently uses three DMLM printers, two of which are used in post-processing systems. By the end of 2020, this number is expected to double, and the plant will reach full capacity between 2022 and 2023-adding 15 DMLM machines.
Mantegazza learned about electron beam melting (EBM) at Avio’s Cameri factory3D printingTechnology, the plant is the world’s largest commercial engine3D printingTurbine blades GE9X.
“When I was in Cameri, we introduced EBM technology to GE and provided learning and guidance for industrialization. In the past two years, we have been learning how to optimize and industrialize DMLM technology. Now, we are finally ready to use it. Used in the production of the first batch of products.”
The two Italian factories often work with the team.



Antroine Townes, head of the ATC plant in West Chester, Ohio.

Antroine Townes, head of the ATC plant, said: “We are currently planning to develop products for about 10 military and civilian aircraft, such as LEAP, GE9X, and of course GE Catalyst. In addition to production, digital IT, R&D and engineering teams also work here. “
Townes and Mantegazza met during their visit to ATC in 2018.
“We started working together about two years ago and will continue to do so for the entire five years. This is definitely our mutual benefit. We exchange knowledge and increase mutual trust. Our work on the Catalyst program is to add all additives The production of parts moved from Ohio to Brindisi. We started with a smaller company and will eventually grow into a larger company. At that time, Brindisi will be self-reliant and committed to Catalyst. Then, we will continue to deal with the additional Parts and other aircraft engines that will have additional parts in the future.”



Dario Mantegazza, head of MFCTG additives at Avio Aero Brindisi, at a meeting in the new plant.

“ATC is an important partner of the Lean Laboratory. During this transfer process, we cooperated with Antroine and our American colleagues every day. This is the only way we can guarantee that the products produced in Brindisi are fully mature. In addition, In Avio Aero, we can also rely on the industrial optimization and development activities carried out in the laboratory in cooperation with the university, just like in TAL.”
Approximately 85% of the products processed on ATC will be used in aviation applications.

GE Catalyst engines are installed in the new test units of GE Aviation Czech and CVUT.

Initially, GE Catalyst planned to conduct its first test flight at the end of 2019. But GE has not yet delivered the engine to Textron Aviation, which means it has not yet conducted a test flight.According to China3D printingWang understands that the first flight will take place sometime this year.

(Editor in charge: admin)