GKN produces Rolls-Royce engine compressor case using 3D printing technology

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Aerospace supplier GKN Aerospace has successfully manufactured a partially 3D printed intermediate compressor case (ICC) for aircraft engine OEM Rolls-Royce. Set to be used in a demonstrator program for Rolls-royce’s upcoming UltraFan engine the ICC was developed as part of Clean Sky 2 Europe’s largest aeronautics research program focused on reducing the CO2 emissions and noise levels of today’s aircraft engines. Henrik Runnemalm Vice President of GKN Aerospace’s Global Technology Centre in Sweden said “The delivery of the UltraFan engine ICC to Rolls-Royce is a true milestone. We are extremely proud to be a partner of the Rolls-Royce team and to contribute to this energy efficient aero-engine of the future.” The UltraFan engine’s ICC. The UltraFan engine The latest entry to the Rolls-Royce engine portfolio is UltraFan. Reportedly offering 25% greater fuel efficiency when compared to the first generation of Trent engines UltraFan features a new engine core architecture. With carbon titanium fan blades and a composite casing the new engine can reduce the weight of an aircraft by up to 680kg. Rolls-Royce intends to do a full engine ground test in 2022 with flight testing set to follow shortly after. “Our first engine demonstrator UF001 is now coming together and I’m really looking forward to seeing it built and ready for test ” said Chris Cholerton Rolls-Royce’s Civil Aerospace President. The upcoming Rolls-Royce UltraFan engine. Manufacturing the UltraFan ICC As a core partner in both Clean Sky 2 and the demonstrator program GKN was responsible for designing and manufacturing the ICC. While the majority of the ICC was manufactured using traditional casting techniques several of the attaching parts were fabricated via metal 3D printing. GKN Aerospace’s ICC manufacturing process received support from the Vinnova-funded IntDemo project and the Västra Götaland Region in Sweden. With projects like UltraFan the additive manufacturing of end-use turbine engine components

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