3D-printed aero engine parts get ready to fly
Additive manufacturing, also known as 3D printing, allows engineers and designers to print complex metal parts directly from a computer file. (Photo: GE)
GE Aviation receives airworthiness qualification from the US Air Force in under a year for the first metal 3D-printed engine part.
GE Aviation has received Engineering Change Proposal approval from the USAF for an F110 additively manufactured sump cover.
This F110 component is the first engine element designed for and produced by metal-additive manufacturing to be qualified by any US DoD entity.
The airworthiness qualification of the sump cover brings Pacer Edge Phase 1a of the pathfinder to its conclusion.
GE leveraged its experience in metal-additive engineering and manufacturing to drive the quick qualification process, which took less than a year.
Phase 1b is already under way and focuses on an out-of-production sump cover housing on the TF43 engine, which has been in service for more than 40 years.
The USAF Propulsion Directorate and RSO invested $10million to fund additional phases of the Pacer Edge programme.
This funding will accelerate the development of a USAF organic additive-manufacturing capability and capacity to design and print flightworthy hardware for military engines, aircraft and support equipment.
The Pacer Edge team is utilising this capability to alleviate hard-to-source and obsolete spare-part constraints for legacy systems.
More from Defence Notes
-
![Amazon Project Kuiper emphasises user-friendly solutions for multi-domain connectivity (Studio)]()
Amazon Project Kuiper emphasises user-friendly solutions for multi-domain connectivity (Studio)
At DSEI 2025, Shephard's Alix Valenti spoke to Project Kuiper's Rich Pang about the importance of enabling seamless communication between allied forces such as NATO members in challenging operational environments.
-
![DSEI 2025: Raytheon UK CEO highlights RTX skills, innovation and UK footprint]()
DSEI 2025: Raytheon UK CEO highlights RTX skills, innovation and UK footprint
At DSEI 2025, James Gray, Managing Director and CEO of Raytheon UK (part of RTX), outlines the company’s century-long presence in the UK and its evolving role across defence, aerospace, cyber, and training domains.
-
![Israel defence ministry pushes ambitious spending plans for tanks, drones and KC-46 aircraft]()
Israel defence ministry pushes ambitious spending plans for tanks, drones and KC-46 aircraft
The procurement and acceleration production plans – some of which still await approval – across the air and land domains will aim to strengthen the operational needs of the Israel Defense Forces.
-
![US reforms its defence acquisition system to focus on commercial capabilities]()
US reforms its defence acquisition system to focus on commercial capabilities
This shift is planned to accelerate the procurement and fielding of capabilities. As part of this strategy, the US also intends modernise its regulations in an attempt to change its bureaucratic and risk-averse culture.
