Pratt & Whitney and GKN Aerospace to 3D Print Large-Scale F135 Engine Case

Aerospace Giants Target Military Engine Production

Pratt & Whitney and GKN Aerospace have signed a Technology Development Agreement to explore the use of additive manufacturing for large structural components of the F135 engine, which powers the F-35 Lightning II family of supersonic stealth strike fighters. The agreement, announced at the Farnborough Air Show, is supported by the Norwegian Defence Materiel Agency (NDMA).

Laser-Directed Energy Deposition at Kongsberg

Development will take place at GKN Aerospace's facility in Kongsberg, Norway, using the company's laser-directed energy deposition with wire (L-DED-w) process. This metal 3D printing technology has been developed and matured over several years and is capable of producing large-scale components with complex geometries.

The goal is to produce a full-scale engine case while maintaining compatibility and interchangeability with the current engine design. Upon completion, this large-scale 3D printed structure is expected to be among the first of its kind at this scale within military engine applications.

Timeline: 2027 Demonstrator, 2028 Certification

A first demonstrator component is expected to be ready by 2027, with full certification targeted for the end of 2028. The project represents a significant step forward in applying additive manufacturing to large-scale, high-performance aero-engine structures.

"This initiative reflects our ambition to further develop and industrialise additive technologies for demanding aerospace applications," said Sébastien Aknouche, Senior Vice President at GKN Aerospace.

"This agreement reflects our continued focus on advancing technologies that support the long-term needs of the F135 program," added Chris Johnson, vice president of the F135 Program at Pratt & Whitney.

What This Means for 3D Printing

The F135 engine case project builds on GKN Aerospace's existing work in metal additive manufacturing, including its 3D-printed fan case mount ring components for Pratt & Whitney GTF engines. If successful, it could pave the way for broader adoption of large-scale metal 3D printing in military aerospace applications, potentially reducing lead times and part complexity for critical engine components.