There are currently 98 patented … Follow GE Aviation on Twitter and YouTube. The Catalyst engine is the world’s first turboprop engine with 3-D printed parts. (Image courtesy of GE.) Up to ten GE Catalyst components will be produced in this area. The probes collect information about vital factors like vibration, torque and thrust and send it to a team of engineers working in a nearby windowless room. ... Case in point: the GE Catalyst Turboprop engine. With advanced manufacturing techniques like 3-D printing, we have reduced 855 parts to 12 components thereby reducing weight, wear and leakage. Find information on the different powders that can be used with GE Additive's additive manufacturing machines. Additive manufacturing is just one more way the Catalyst engine is a force multiplier for the future of turboprop propulsion. According to GE Aviation, the GE Catalyst is “the first clean-sheet engine in more than 30 years for the turboprop segment,” and represents the promise that GE Aviation and GE Additive see in 3D-printing technologies. Photo courtesy of Nick Hurm, GE Additive. GE's Catalyst engine features a single-lever engine and propeller control that simplifies engine management. From tooling/prototyping to mass production of engine, transmission, and chassis components, the ready are evaluating how additive can drive greater returns on investment. For engineers trained on traditional casting and welding processes, that requires a whole new thought process. Wherever you are on the path to full metal additive production, our team can help get you there faster. Additive manufacturing allows GE to create advanced, cost effective parts at an accelerated rate that reduce fuel burn, decrease weight and increase durability. GE’s Catalyst is the first clean-sheet turboprop engine to hit the general aviation market in more than 30 years, enabling better performance through proven GE commercial technology. An integrated propulsion control system automatically optimizes fuel flow, prop pitch and speed, bleed valves, and variable stators for maximum efficiency in all conditions. GE’s Catalyst engine, which was built using additive manufacturing for small commercial turboprop aircraft, was developed in 50 percent less time than it normally would have taken, and testing took only six months versus a year. At GE Additive, we continue to work every day to bring the transformative power of advanced manufacturing to businesses around the globe. The result is greater availability and ultimately lower cost of ownership for the life of the engine. Our team offers workshops, application sprints and engineering and consulting services to fast-track your path to production. Saving valuable time. For example, the T901 includes an additive part that reduces an assembly of more than 50 subcomponents into one part. Cooled turbine blades and multi-stage turbines, High OPR compressors and Variable Stator Vanes. “Everything is done automatically. Direct Metal Laser Melting (DMLM) technology. Thanks to additive manufacturing, the Catalyst program has benefited in the development of the engine with a reduction of cycle time, as well as fewer first article inspections, less inventory, … Feel free to look ahead. What materials are used in additive manufacturing? GE’s Catalyst on an engine test stand in Prague. "The GE Catalyst engine is redefining what a turboprop can do for pilots, airframers and operators in business and general aviation," said Paul Corkery, general manager for GE Aviation Turboprops. News of their success in 3D-printing a mini-jet engine has gathered some attention. GE Aviation’s GE9X engine, which is equipped with more than 200 metal additively manufactured turbine blades, has received certification from the Federal Aviation Administration (FAA).. This enables it to deliver 15% lower fuel burn & 10% higher cruise power compared to other engines. To stay at the forefront, you have to radically change the way you design and build combat air systems, combat vehicles, complex surface ships and more. Over the course of just a few years, additive manufacturing (AM) seems to have emerged as a catalyst in reshaping product development and, perhaps, the manufacturing business model itself. Innovation, advanced manufacturing and digital analytics liberate aircraft design engineers from the conventional trade-offs they have to make in weight, speed, fuel consumption, range, and so on. According to company officials, the GE Catalyst engine is the first all-new, clean-sheet engine in more than 30 years in the general aviation market. GE Aviation has a global service network to support these offerings. General Electric Aviation is one of the top three manufacturers of commercial jet engines in the world and the most modern manufacturing technique available—additive manufacturing or 3-D printing—is enabling great leaps in design and engineering. The 30 metallic additive parts certified to date replace >50 parts. Same amount of fuel, payload and mission you can have a larger cabin. GE’s Catalyst engine undergoes testing at GE Aviation’s facility in Prague. ... One of the best examples of part consolidation with 3D printing is GE’s Catalyst Advanced Turboprop engine, which was reduced from a whopping 852 parts to a mere 12; the bearing and sump assemblies were reduced from 80 parts to 1! The engine also sports technology called full authority digital engine and propeller control, or FADEPC, which is common in jets but has never been used in commercial turboprop planes. GE’s Catalyst engine, which was built using additive manufacturing for small commercial turboprop aircraft, was developed in 50 percent less … The T901 GE engine. The Aerospace industry is a pioneering sector for additive manufacturing and is paving the way to serial production. A civilian turbine engine, the Catalyst, leverages similar technology and is also based on the existing T700 program. "It acts as a… Like the T901, it includes variable stator vanes and 3D printed parts using additive manufacturing… Additive manufacturing has allowed this industry to increase patients quality of life around the world. 100% European, the engine features 98 patented technologies and several parts are made using Additive Manufacturing (the first time such a high proportion have been seen in one engine). “GE Aviation and this year’s winners exemplify the spirit and innovations that are transforming our industry to meet the challenges of tomorrow,” said Joe Anselmo, editorial director of the Aviation Week Network. GE Aviation’s Additive Technology Center is a state of the art additive manufacturing (3D printing) facility located in West Chester, Ohio. This reduction in complexity speeds production, reduces Fuel Burn and weight, and increases durability with fewer seams and tighter tolerances. GE’s Catalyst engine, which was built using additive manufacturing for small commercial turboprop aircraft, was developed in 50 percent less time than it normally would have … The engine ran for the first time in December 2017 at GE Aviation’s facility in Prague, Czech Republic, and a second engine … The technique also allowed the team hasten its development “from a dream to a reality in just two years,” Gordie Follin, the executive manager of the Catalyst program, told GE Reports. Reliability is the benchmark of proven technology. And since they’re capable of achieving high levels of accuracy, even on intricate shapes and geometries, these machines open up new design possibilities across a multitude of applications. Imagine a stack of some 850 engine parts sitting next to a stack of 12 parts. Essentially the engine’s digital brain, the technology will allow pilots to control a plane with just a single lever, instead of three. It has been said since the development of the Catalyst, that additive manufacturing has made it possible to reduce about 855 parts of the engine to only 12 thanks to the use of 3D printing, but the Brindisi … “With additive manufacturing, we’re disrupting the whole production cycle,” he says. Its Catalyst engine for small commercial turboprop aircraft was designed and built with additive processes from the start. General Electric (GE), on the hunt for ways to build more than 85,000 fuel nozzles for its new Leap jet engines, is making a big investment in 3D printing. Learn more about our leadership, our history and how we became one team — GE Additive. The GE9X also includes 3D printed fuel nozzles produced by the GE Additive division, parts made from light- and heat-resistant ceramic composites, and other new technologies. By: Lindsey Quinn. Leverage the knowledge and expertise of GE Additive AddWorks team and shorten your learning curve with the adoption of additive technology. Top image: The GE Catalyst on a test stand in Prague. At GE Additive, we continue to work every day to bring the transformative power of advanced manufacturing to businesses around the globe. The T901 GE engine. GE’s Catalyst Engine. The result is a simplified cockpit that includes a single-lever power control, fewer instruments to monitor and more precise engine control. 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