Access the latest press releases, media contacts, and press tools. We’re continuing to do all we can to support our customers and employees during this unprecedented time. A single machine can simultaneously print six turbine blades directly from a computer file by using a powerful 3-kilowatt electron beam. GE Aviation is a world-leading provider of aircraft engines, systems and avionics. GE Aviation Auburn currently operates more than 40 metal 3D printers for the purpose of part production. Sixty other designs are being perfected, some reducing the number of parts … Explore GE’s recent and historic SEC filings. 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. The two … Aircraft engineering . “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. Explore the latest stories, news, downloads, and press tools. GE plans to produce 100,000 3D-printed components for the next-generation GE9X and Leap models Courtesy of GE Aviation 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. Creating the energy technologies of the future and improving the power networks that we depend on today. Image credit: Tomas Kellner for GE Reports. Above: GE Aviation's Additive Technology Center in Cincinnati might easily be the world’s largest and most advanced 3D-printing and development center. As a result, more than a third of the engine is 3D-printed. GE's dedicated team, leading technology, and global reach and capabilities help the world work more efficiently, reliably, and safely. 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. 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. 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. The technology's potential is enormous, but GE engineer Peter Martinello offers a dose of perspective. Access GE’s recent and historic Annual Reports and accompanying materials. 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. “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.”. The 3D printed fuel nozzle inside the GE9X was 3D printed by Morris Technologies, which was acquired by GE in 2012. Transforming how industry solves its toughest challenges by bringing simplicity, speed and scale to digital transformation. They selected Concept Laser’s M2 printer, a fast, midsize machine that uses a pair of lasers to print four brackets at a time. Read the latest GE financial news releases and stories. Ignition, Combustion and Detonation engineering . “In the design of jet engines, complexity used to be expensive," Ehteshami says. 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 … Learn about governance at GE, including the latest Proxy Statement and information about the GE Board of Directors. The blades were cracking when Abrate and the team tried to separate them from the platform on which they were printed. “Air flow is pretty critical in terms of getting parts with good internal and external quality,” Brandel says. But take a short ride through the rolling fields of the fertile Po Valley that surround it and you’ll discover a startling contrast. He says that when GE acquired Avio Aero in 2013, “it was really fortunate because everything accelerated after that.”. “This is true if you have to print just one part,” he says. GE's innovation engine where ideas become reality to create a better world and deliver differentiated tech across the company's industrial portfolio. The 3D-printed blades spin inside the engine at 2,500 times per minute and face searing heat and titanic forces. A culture of integrity, compliance, safety, and respect for human rights, while reducing our environmental footprint. Starting with rockets, our Stargate factory vertically integrates robotics, software, and patented 3D printing technologies to digitize manufacturing. A GEnx engine on a test stand in Peebles, Ohio. Tune in or catch up on GE’s latest investor events and reports. 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. Creating the energy technologies of the future and improving the power networks that we depend on today. “They were already convinced,” Abrate says. Learn how we’re delivering on our priorities. 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. GE Aviation plans to mass-produce them on Concept Laser 3D printers. The Northern Italian town of Cameri could be easily mistaken for a quiet farming commune. Offering a suite of products to help unlock the full potential of additive manufacturing. GE Aviation acquired Avio Aero in 2013 and developed the GE9X engine for Boeing’s next-generation 777X jets. But in order to make the approach economical, they had to print four brackets at a time. Fortunately for GE, the company now owns two of the largest metal 3D printer … At GE, we rise to the challenge of building a world that works. 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. Accomplished leaders building GE’s legacy. For the last four years GE has been manufacturing 3D printed fuel nozzles for the A320's jet engine. The Cameri plant employs eight specialized hourly workers feeding the machines with powder, removing and cleaning the printed parts, and doing maintenance. Offering a suite of products to help unlock the full potential of additive manufacturing. “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. 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. 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. Working in a parallel track, a team of engineers was readying the Concept Laser machine for mass production. “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.”. GE's innovation engine where ideas become reality to create a better world and deliver differentiated tech across the company's industrial portfolio. “We could see how difficult it was to make these blades,” Abrate says. GE Aviation is a world-leading provider of aircraft engines, systems and avionics. There are also nine manufacturing engineers, who keep improving the production process. “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. “These are big blades,” says Giorgio Abrate, general manager for engineering at Avio Aero. Twenty parts were once machined together to construct part of the CFM Leap engine. 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. Got broken things that need a little TLC? We build intelligent devices, data analytics, applications and services to enable healthcare practitioners to deliver care more efficiently and with better outcomes. Discover how our people & technology are solving global issues, improving lives, and changing industries. “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.”. Learn more about our culture, businesses, and life at GE. Explore a career with us. “A lot of the things we do here, we are doing for the very first time. Top: Brandel (left) and Martinello (right) hold in their hands 3D-printed brackets for the GEnx-2B engine. Mohammad Ehteshami, who launched GE Additive, expects the industry to grow from $7 billion today to $80 billion in a decade. Getting the part ready for printing was another riddle. “We ran a lot of experiments to get the job right.” “The Lockheed plant made the town become very visible among aerospace companies. “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. 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. Discover how our people & technology are solving global issues, improving lives, and changing industries. GE Aviation plans to begin mass-producing the GEnx parts this month at its factory in Auburn, Alabama. Learn how we’re delivering on our priorities. GE also opened additive manufacturing labs in the U.S. focusing on the technology. That created some hand-wringing. Contact information for general inquiries and feedback. Learn about governance at GE, including the latest Proxy Statement and information about the GE Board of Directors. “We were being charged a significant amount for these parts,” Gatlin says. Back in Cincinnati, Gatlin, Martinello, Brandel and their colleagues are already working on their next projects. The printed plane engine has arrived. 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. “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. 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