GE Aerospace has had a new turboprop engine certified. Thanks to 3D printing, the performance figures are impressive.
Donald Trump will only be moderately enthusiastic about this: US engine giant GE Aerospace has had a new, highly efficient turboprop engine certified by the Federal Aviation Administration (FAA). The flagship "Catalyst" engine is said to consume 18% less fuel. At the same time, it allows a 10% higher cruising speed. And who designed/built it? Europeans!
Several GE subsidiaries were involved in the development of the engine, above all Avio Aero from Italy. The parts came mainly from Turin, Warsaw, Prague, Bielsko-Biała and Cameri.
A third of the internal components are printed
The engine's exceptional key figures are made possible thanks to additive manufacturing. According to 3Dprint.com, almost a third of the internal components are built up in layers. This saves a lot of weight. But that is not the only advantage: assembly and maintenance costs are also significantly reduced. Where previously 855 individual parts were assembled, twelve printed components are now used.
The fuel costs for turboprop engines are between $250 and $600 per hour. Around 1800 turboprop aircraft are currently delivered every year in the USA alone.
Catalyst is the first turboprop engine of the 21st century to be certified to the latest standards. Riccardo Procacci, President and CEO, Propulsion and Additive Technologies at GE Aerospace, said: "The certification of the Catalyst engine is a significant milestone for our company and a proud moment for all of our team members who have dedicated themselves to the design, development and testing of this brand new European turboprop engine."
GE Aerospace is also active in the defense sector
GE Aerospace is a global leader in aerospace propulsion, services and systems with an installed base of around 45,000 civil and 25,000 military aircraft engines. The number of employees currently stands at around 53,000 and the Group's metal printing operations are largely based on German technology. GE Additive, now Colibrium, acquired Concept Laser GmbH from Lichtenfels in 2016. However, Concept founder Frank C. Herzog is still very active in the field of additive manufacturing:
