The Cameri plant employs eight specialized hourly workers feeding the machines with powder, removing and cleaning the printed parts, and doing maintenance. Our proprietary process optimizes every aspect of aerospace development and enables faster, more frequent, and lower cost access to space. But additive allows you to get sophisticated and reduces costs at the same time. Read More Learn more about our culture, businesses, and life at GE. “Fundamental engineering principles still apply. “In the design of jet engines, complexity used to be expensive," Ehteshami says. The Blade Runners: This Factory Is 3D Printing ... - GE.com Accomplished leaders building GE’s legacy. Our technology, global network, and exceptional team is fueled by a mission—building a world that works. Access GE’s recent and historic Annual Reports and accompanying materials. The aluminium manifold inlet, 3D printed on a Concept Laser X LINE 2000R from GE Additive, took five days to complete. A single machine can simultaneously print six turbine blades directly from a computer file by using a powerful 3-kilowatt electron beam. 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. “These are big blades,” says Giorgio Abrate, general manager for engineering at Avio Aero. A model of a 2-spool high bypass turbofan. The beam “grows” the blades, which are 40 centimeters long, by welding together thin layers of titanium aluminide powder, one after another. Additive manufacturing is still a young industry, albeit one going through a growth spurt. There are also nine manufacturing engineers, who keep improving the production process. A GEnx engine on a test stand in Peebles, Ohio. But the project was only half done. We build intelligent devices, data analytics, applications and services to enable healthcare practitioners to deliver care more efficiently and with better outcomes. “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. Contact information for general inquiries and feedback. We’re continuing to do all we can to support our customers and employees during this unprecedented time. Image credit: GE Aviation. GE Additive Print Services Center is a full-scale, certified AS9100/ISO9001 additive printing and post-processing facility. “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. Mohammad Ehteshami, who launched GE Additive, expects the industry to grow from $7 billion today to $80 billion in a decade. “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. “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.”. Together with our customers, we’re proving that no one is ever limited to only affordable, reliable, or sustainable energy. I designed the whole engine from scratch with visual cues to certain existing engines. We’re deeply proud of GE employees around the world rising to the challenge. At GE, we rise to the challenge of building a world that works. It weighs 50 percent less than the metal alloys typically used in aviation. Aircraft engineering . GE also opened additive manufacturing labs in the U.S. focusing on the technology. Explore GE’s recent and historic SEC filings. 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. Learn how we’re delivering on our priorities. Tune in or catch up on GE’s latest investor events and reports. Image credit: Adam Senatori for GE Reports 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. Above: GE Aviation's Additive Technology Center in Cincinnati might easily be the world’s largest and most advanced 3D-printing and development center. According to GE … By embracing diverse teams and perspectives, we are better equipped to build a world that works. This week GE released this great GIF of its 1,300-horsepower advanced turboprop (ATP) engine in which more than one-third of … 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. Twenty parts were once machined together to construct part of the CFM Leap engine. Transforming how industry solves its toughest challenges by bringing simplicity, speed and scale to digital transformation. A culture of integrity, compliance, safety, and respect for human rights, while reducing our environmental footprint. Access important shareholder information. In 2016, GE  took a majority stake in Arcam and launched GE Additive, a new business focusing on additive manufacturing technologies like 3D printing. GE's dedicated team, leading technology, and global reach and capabilities help the world work more efficiently, reliably, and safely. GE's innovation engine where ideas become reality to create a better world and deliver differentiated tech across the company's industrial portfolio. It’s about understanding what it can do, and how it can improve your designs.”, https://www.facebook.com/GE/videos/10160864544500422/. 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. 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. 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. “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 selected Concept Laser’s M2 printer, a fast, midsize machine that uses a pair of lasers to print four brackets at a time. GE's innovation engine where ideas become reality to create a better world and deliver differentiated tech across the company's industrial portfolio. The first GE jet engine to actually take flight while using a 3-D-printed part is the GE90. The engine in question is actually a 3D-printed model, designed by GE. When it comes to flying, he says, every ounce counts. Discover how our people & technology are solving global issues, improving lives, and changing industries. Access important shareholder information. These and other new materials and technologies will help make the engine 10 percent more fuel-efficient than its predecessor, the GE90. Learn more about our culture, businesses, and life at GE. Access the latest press releases, media contacts, and press tools. Our technology, global network, and exceptional team is fueled by a mission—building a world that works. 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. “There’s no part that just comes off a printer and goes straight into the engine,” Gatlin says. But Martinello and his colleagues have just taken that feat to a new level. Learn how we’re delivering on our priorities. We connect capital to infrastructure and deliver innovative financial solutions that help make the world work better. GE Aviation plans to begin mass-producing the GEnx parts this month at its factory in Auburn, Alabama. “It’s a highly collaborative process,” Martinello says. “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.”. 3D printing has rightfully gotten a lot of buzz because of the marvels it can do. The printed plane engine has arrived. Transforming how industry solves its toughest challenges by bringing simplicity, speed and scale to digital transformation. Tune in or catch up on GE’s latest investor events and reports. Commercializing GE’s technology and IP to accelerate growth and achieve market differentiation. 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. The goal is to help organizations adopt additive manufacturing technology faster by offering the ability to take parts from an idea to production. 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. The 3D-printed blades spin inside the engine at 2,500 times per minute and face searing heat and titanic forces. The technology's potential is enormous, but GE engineer Peter Martinello offers a dose of perspective. 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. But take a short ride through the rolling fields of the fertile Po Valley that surround it and you’ll discover a startling contrast. Read on to see how. Getting the part ready for printing was another riddle. Ignition, Combustion and Detonation engineering . “The Lockheed plant made the town become very visible among aerospace companies. “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 blades were cracking when Abrate and the team tried to separate them from the platform on which they were printed. Creating the energy technologies of the future and improving the power networks that we depend on today. The size of a walnut, this wickedly complex metal part was previously made from 20 components. He says that when GE acquired Avio Aero in 2013, “it was really fortunate because everything accelerated after that.”. Explore a timeline of GE technologies that have spurred transformation across the world. The submarine, however, had a secret weapon: a powerful Arcam printer that print parts from TiAl powder. The two … Running more experiments, he also learned that preheating the powder before printing removed much of the residual stress from the finished parts. 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. The team also implemented small design tweaks that reduced the bracket’s weight by 10 percent. Commercializing GE’s technology and IP to accelerate growth and achieve market differentiation. GE Aviation Auburn currently operates more than 40 metal 3D printers for the purpose of part production. Call it the little engine that could. By then, Avio Aero bought ProtoCast and signed an exclusive agreement with Arcam to acquire a set number of the modified machines. They’ve identified more than 100 components that could be printed. Answers to popular and relevant inquiries. 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. Sixty other designs are being perfected, some reducing the number of parts … GE Aviation is a world-leading provider of aircraft engines, systems and avionics. “It looks like one of those woodblock puzzles, where all the pieces fit together,” Gatlin says. Access the latest press releases, media contacts, and press tools. By embracing diverse teams and perspectives, we are better equipped to build a world that works. 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 … A few weeks ago General Electric announced that the FAA (U.S. Federal Aviation Administration) cleared their first 3D printed part to fly. Avio Aero started exploring 3D printing more than a decade ago. Above: The 3D printed nozzle combined all 20 parts into a single unit, but it also weighed 25 percent less. At GE, we rise to the challenge of building a world that works. Read the results of the 2020 GE Global Innovation Barometer, titled “Pride and Protectionism: A Quest for Innovation Agency.”. “We just had to machine some bolt holes and some clevis pins and we were done,” he says. I think that breeds a certain amount of excitement, a certain amount of energy, and requires a certain culture.” Image credit: GE Aviation. When Avio Aero showed GE what it was doing with the wonder metal, the American company quickly grasped the magnitude of the breakthrough. Brandel and his colleagues spent several months making sure the machines were ready for prime time. The list includes printing parameters, but also heat treatment and inspection steps. 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. “It was really a garage,” Abrate recalls. We connect capital to infrastructure and deliver innovative financial solutions that help make the world work better. 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. 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. 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. 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