Pratt & Whitney, a subsidiary of RTX (formerly Raytheon Technologies), is using 3D printing for engine manufacturing transforming the military production process, marking a significant step forward for the aerospace industry. This novel approach is transforming the landscape of engine design, manufacturing, and maintenance.
Pratt & Whitney is also using additive manufacturing on large engines such as the F135, developed for the Lockheed Martin F-35 Lightning II, and the TF33, which powers the US Air Force’s B-52 Stratofortress long-range, heavy bomber.
3D Printing for Engine Manufacturing
Pratt & Whitney’s GATORWORKS team has successfully redesigned the TJ150 engine, a compact powerhouse used in UAVs and missiles, using a technique known as unitisation. This process has reduced the engine’s part count from over 50 to only a few, while maintaining its robust performance.
Jesse Boyer, a fellow for additive manufacturing at Pratt & Whitney, explained, “Additive manufacturing is transforming the way we design and manufacture products, offering us unprecedented flexibility to realize designs that would be difficult if not impossible with traditional methods.”
The entire redesign process, from concept to engine testing, took only eight months, demonstrating the agility and efficiency of additive manufacturing techniques.
Pratt & Whitney – Streamlining Production
The F135 engine, which powers the F-35 Lightning II fighter jet, is another example of additive manufacturing. Pratt & Whitney has used 3D printing for the Turbine Exhaust Case trailing edge box, a critical component that directs exhaust gases.
The transition from traditional hydroforming to additive manufacturing has resulted in significant benefits. “Unitisation saves costs by reducing our part count, and it also improves our lead time because you’re simplifying the supply chain,” Boyer noted. The potential savings from castings and mouldings alone are estimated to be around $1 billion.
Sustaining Legacy Fleets
Additive manufacturing is proving critical for preserving legacy military aircraft. Spare parts for engines such as the TF33, which powers the B-52H Stratofortress, have become increasingly difficult to obtain over the years.
“Many parts haven’t been made in over 20 years, and most original suppliers no longer exist.”
– Joe Ott, TF33 and F100 technology manager at Pratt & Whitney
To address this, the company used additive manufacturing to redesign and manufacture a flight-worthy bracket for the TF33 engine in under nine months. Field testing began in 2023, with ongoing evaluations aiming for full production implementation.
This application of 3D printing allows for on-demand part production, significantly lowering costs and lead times associated with traditional manufacturing methods for legacy components.
Industry-Wide Impact
The adoption of additive manufacturing by a major player such as Pratt & Whitney represents a significant shift in the aerospace industry. The technology provides several key benefits:
- Increased design flexibility for development engines.
- Simplified supply chains.
- On-demand replacement of rare legacy engine components.
- Reduced production time and cost.
“Our government customers are looking for unique and innovative ways to design, develop and deploy capability. More and more, we are partnering to explore non-traditional approaches to achieve this.”
– Chris Hugill, senior director of GATORWORKS
Looking Ahead
As Pratt & Whitney expands its use of additive manufacturing, it is looking into applications for other engine components, such as rotating hardware. The technology’s ability to tailor material properties and manage stress distribution may result in more durable parts and advancements in engine design.
The aerospace industry is witnessing a paradigm shift in manufacturing techniques, with additive manufacturing leading the way. As companies like Pratt & Whitney continue to innovate, more efficient, cost-effective, and agile manufacturing methods will become the norm in aerospace engineering.
This manufacturing revolution not only promises to keep legacy aircraft flying, but it also paves the way for the next generation of aerospace technologies, ensuring that the industry remains at the forefront of innovation in the coming years.
