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

Major Aerospace Partnership for F-35 Engine Components

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

Producing a Full-Scale Engine Case

The joint development programme aims to demonstrate the feasibility of producing a large-scale engine case using metal 3D printing. Upon completion, this structure is expected to be among the first of its kind at this scale within military engine applications.

Development work will be led from GKN Aerospace's facility in Kongsberg, Norway, and will utilise GKN Aerospace's laser-directed energy deposition with wire (L-DED-w) process — a technology developed and matured over several years. The ambition is to produce a full-scale component while maintaining compatibility and interchangeability with the current engine design.

Timeline and Milestones

The partners have outlined a clear development timeline:

• 2027: First demonstrator component expected to be ready
• End of 2028: Target for full product certification

The initiative represents a significant step forward in applying additive manufacturing to large-scale, high-performance aero-engine structures.

Executive Quotes

Sébastien Aknouche, Senior Vice President, GKN Aerospace: "I am pleased to see this collaboration bringing together strong industrial capabilities and advanced manufacturing expertise. This initiative reflects our ambition to further develop and industrialise additive technologies for demanding aerospace applications."

Chris Johnson, Vice President of the F135 Program, Pratt & Whitney: "This agreement reflects our continued focus on advancing technologies that support the long-term needs of the F135 program. We appreciate the collaboration with GKN Aerospace as we explore new manufacturing approaches that contribute to future engine readiness."

Broader Context

This partnership builds on GKN Aerospace's existing work with Pratt & Whitney on the GTF engine family, where the company has already produced 3D-printed Fan Case Mount Rings and Fan Spacers using L-DED-w technology. That program was described as the largest fully automated deposition of AM to be certified on commercial aircraft.

The F135 engine, which powers the F-35A, F-35B, and F-35C variants, is one of the most advanced fighter engine programs in the world. Applying additive manufacturing to its large structural components could significantly reduce weight, simplify assembly, and improve supply chain resilience for the Pentagon's flagship stealth fighter program.