The 100,000th offline! GE Aviation’s new milestone in mass production of 3D printed fuel nozzles

August 20, 2021, GE
aviation
The Additive Manufacturing Center recently achieved a critical milestone, their 100,000th3D printingThe engine fuel nozzle is off the assembly line.What’s amazing is that these fuel nozzles are made entirely of metal3D printingIt is produced in a way that has reached the 100,000-level production scale, which was unthinkable before.
GE Aviation’s Auburn plant began producing fuel nozzles for aircraft engines in 2015. In October 2018, GE Aviation celebrated its 30,000th3D printingThe fuel nozzle was successfully shipped.Now, three years later, GE Aviation has produced another 70,0003D printingFuel nozzles, bringing the total to 100,000.

This pair3D printingThe industry is of great significance, and it also breaks the “3D printingCannot be used for mass production” curse.
Eric Gatlin, general manager of additive manufacturing at GE Aviation, added: “3D printingTechnology has a bright and exciting future. “

3D printingWhat are the jet engine nozzles used for?

GE Aviation3D printingThe fuel nozzles are used in LEAP engines. According to different engine models, each engine needs to install 18 or 19 fuel nozzles. After the nozzles were certified for flight in 2016, the LEAP engine orders totaled more than 14,000 at the 2017 Paris Air Show, which means a minimum of 250,000 fuel nozzles are required.

LEAP is a new generation of aero engine developed by CFM, a 50% joint venture between GE and French Safran Group. It has better fuel economy and lower carbon dioxide emissions. It is now widely used in Boeing 737s. , Airbus A320, and my country’s C919 single-aisle passenger aircraft. In 2014, due to the use of 3D fuel nozzles, its performance has been further improved (more efficient mixing and injection of fuel).

Afterwards, the fuel nozzles produced in Auburn were gradually installed on LEAP engines, which were put into use in 2016 and exceeded 10 million flight hours this year. The fleet provides operators with 15% higher fuel efficiency than the previous generation of engines.

Why use3D printingTechnology to produce fuel nozzles?

The reason why GE Aviation switched to3D printingThe technology produces fuel nozzles because the new design scheme and manufacturing process have been fully verified and completely surpassed the traditional manufacturing methods.

Combining the traditional double-loop pre-mixed suspension flow with LEAP 3D printingAfter comparing the fuel nozzles, you will find the performance in several major indicators:

● The fuel nozzle, which originally required 20 parts to be assembled, is directly designed into one part and printed and formed at one time;

● Due to the reduction of parts and redesign, the weight is reduced by 25%;

● The cost of manufacturing has been reduced by 30%;

● The life of components is extended by 5 times;

● Inventory has been reduced by 95%;

With such a rolling advantage, GE Aviation has no reason not to use3D printingTechnology to replace traditional technology.

GE Aviation3D printingWhat enlightenment does the fuel nozzle bring to us?

GE Aviation3D printingMass production case, it can be said to3D printingThe large-scale application of technology brings confidence,3D printingIt can be used for large-scale production.

Of course, we also need to find the right application scenarios, and we need to make full use of innovative designs.3D printingThe advantages of technology. At the same time, it can also have a certain cost advantage.We need to think about this problem from at least five dimensions. If there are advantages in the five dimensions of performance, efficiency, cost, life, and certification, then3D printingIt can completely replace the traditional production process. If there is an advantage in some of these dimensions, then it can only be partially replaced.

(Editor in charge: admin)