Image credit: GE Aviation. 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. Explore a career with us. 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 Auburn currently operates more than 40 metal 3D printers for the purpose of part production. Our technology, global network, and exceptional team is fueled by a mission—building a world that works. “In the design of jet engines, complexity used to be expensive," Ehteshami says. We connect capital to infrastructure and deliver innovative financial solutions that help make the world work better. But early runs with ProtoCast’s laser-powered printers failed. The GE90 is one of the world’s most powerful jet engines. We build intelligent devices, data analytics, applications and services to enable healthcare practitioners to deliver care more efficiently and with better outcomes. 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. 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. In 2016, GE  took a majority stake in Arcam and launched GE Additive, a new business focusing on additive manufacturing technologies like 3D printing. It’s just a new tool that you have at your disposal. 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. Access the latest press releases, media contacts, and press tools. The Blade Runners: This Factory Is 3D Printing ... - GE.com Access important shareholder information. Answers to popular and relevant inquiries. 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. But  TiAl is also very brittle. But in order to make the approach economical, they had to print four brackets at a time. The Cameri plant employs eight specialized hourly workers feeding the machines with powder, removing and cleaning the printed parts, and doing maintenance. GE's innovation engine where ideas become reality to create a better world and deliver differentiated tech across the company's industrial portfolio. Learn how we’re delivering on our priorities. GE has received orders for 1,658 LEAP and other engines, which can each include up to 19 3D printed fuel nozzles. But take a short ride through the rolling fields of the fertile Po Valley that surround it and you’ll discover a startling contrast. Working in a parallel track, a team of engineers was readying the Concept Laser machine for mass production. The blades from Cameri are already working inside the first GE9X engines, which GE started testing last year. He says that when GE acquired Avio Aero in 2013, “it was really fortunate because everything accelerated after that.”. “It looks like one of those woodblock puzzles, where all the pieces fit together,” Gatlin says. GE Aviation was developing its own 3D printing program near its headquarters in Cincinnati. GE Additive Print Services Center is a full-scale, certified AS9100/ISO9001 additive printing and post-processing facility. GE Aviation acquired Avio Aero in 2013 and developed the GE9X engine for Boeing’s next-generation 777X jets. 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. 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. GE's dedicated team, leading technology, and global reach and capabilities help the world work more efficiently, reliably, and safely. Contact information for general inquiries and feedback. 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. 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. The first GEnx engines used brackets made with traditional methods such as milling. “A lot of the things we do here, we are doing for the very first time. The size of a walnut, this … The submarine, however, had a secret weapon: a powerful Arcam printer that print parts from TiAl powder. The size of a walnut, this wickedly complex metal part was previously made from 20 components. Explore GE’s recent and historic SEC filings. The 3D printed fuel nozzle inside the GE9X was 3D printed by Morris Technologies, which was acquired by GE in 2012. Getting the part ready for printing was another riddle. Commercializing GE’s technology and IP to accelerate growth and achieve market differentiation. “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.”. A few weeks ago General Electric announced that the FAA (U.S. Federal Aviation Administration) cleared their first 3D printed part to fly. We build intelligent devices, data analytics, applications and services to enable healthcare practitioners to deliver care more efficiently and with better outcomes. Commercializing GE’s technology and IP to accelerate growth and achieve market differentiation. The blades were cracking when Abrate and the team tried to separate them from the platform on which they were printed. A culture of integrity, compliance, safety, and respect for human rights, while reducing our environmental footprint. GE's dedicated team, leading technology, and global reach and capabilities help the world work more efficiently, reliably, and safely. “Air flow is pretty critical in terms of getting parts with good internal and external quality,” Brandel 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. Read More Call it the little engine that could. “The location was part of our strategy,” Abrate says. June 26, 2017 Staff. 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. What if a fix was as simple as whipping up your own 3D printed parts? Learn about governance at GE, including the latest Proxy Statement and information about the GE Board of Directors. But Martinello and his colleagues have just taken that feat to a new level. Jet engine designers love this strong, heat-resistant wonder material, also known as TiAl. 3D printing has rightfully gotten a lot of buzz because of the marvels it can do. “There’s no part that just comes off a printer and goes straight into the engine,” Gatlin says. GE Aviation plans to begin mass-producing the GEnx parts this month at its factory in Auburn, Alabama. That’s a big deal given that fuel accounts for about 19 percent of an airline’s operating costs. Together with our customers, we’re proving that no one is ever limited to only affordable, reliable, or sustainable energy. The team also implemented small design tweaks that reduced the bracket’s weight by 10 percent. GE's innovation engine where ideas become reality to create a better world and deliver differentiated tech across the company's industrial portfolio. “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. Got broken things that need a little TLC? It weighs 50 percent less than the metal alloys typically used in aviation. 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. Fortunately for GE, the company now owns two of the largest metal 3D printer … The Northern Italian town of Cameri could be easily mistaken for a quiet farming commune. At GE, we rise to the challenge of building a world that works. “They were already convinced,” Abrate says. Explore a career with us. The two … GE Aviation is a world-leading provider of aircraft engines, systems and avionics. The designers reduced 855 separate parts down to just 12. 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. 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. 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. Now there's only one piece—and it's five times stronger. A single machine can simultaneously print six turbine blades directly from a computer file by using a powerful 3-kilowatt electron beam. 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 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. “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. 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. 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. Learn more about our culture, businesses, and life at GE. 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. 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. 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. That created some hand-wringing. 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. Says one of the engineers, Dario Mantegazza, about 3D printing: “You have the ultimate manufacturing freedom.”. Ignition, Combustion and Detonation engineering . “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. Explore the latest stories, news, downloads, and press tools. For the last four years GE has been manufacturing 3D printed fuel nozzles for the A320's jet engine. By embracing diverse teams and perspectives, we are better equipped to build a world that works. “When the GEnx program kicked off, they just hogged the brackets out of a big block of metal,” Martinello says. A culture of integrity, compliance, safety, and respect for human rights, while reducing our environmental footprint. GE’s LEAP engine with 3D printed parts helps rake in $31 B at Paris Air Show. “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. These and other new materials and technologies will help make the engine 10 percent more fuel-efficient than its predecessor, the GE90. More than a third of the ATP is 3D-printed from advanced alloys. 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. Mohammad Ehteshami, who launched GE Additive, expects the industry to grow from $7 billion today to $80 billion in a decade. Together with our customers, we’re proving that no one is ever limited to only affordable, reliable, or sustainable energy. 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. He says this is especially important in aviation because of tight FAA regulations due to the importance of safety and quality in air travel. Answers to popular and relevant inquiries. Read the latest GE financial news releases and stories. Result, more frequent, and doing maintenance few weeks ago general Electric announced that FAA!, data analytics, applications and services to enable healthcare practitioners to deliver more! 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