Offering a suite of products to help unlock the full potential of additive manufacturing. Explore GE’s recent and historic SEC filings. We’re deeply proud of GE employees around the world rising to the challenge. “These are big blades,” says Giorgio Abrate, general manager for engineering at Avio Aero. The team also implemented small design tweaks that reduced the bracket’s weight by 10 percent. Explore a career with us. But the part for the GEnx, a simple bracket the size of a human rib that holds open the engine cover during servicing, had few of these qualities. To keep an eye on the conditions inside the machines, the engineers installed sensors and high-resolution cameras to monitor the power and stability of the laser, the oxygen levels in the printing chamber and other factors. “At that point, we knew what to do,” Abrate says. But Martinello and his colleagues have just taken that feat to a new level. Transforming how industry solves its toughest challenges by bringing simplicity, speed and scale to digital transformation. Read the latest GE financial news releases and stories. Until 3D printing came along, the only way to shape it involved molding, a somewhat dirty process that requires expensive tools. “The location was part of our strategy,” Abrate says. But the project was only half done. The 3D printed fuel nozzle inside the GE9X was 3D printed by Morris Technologies, which was acquired by GE in 2012. For example, they are working on significant cost- and weight-reduction projects across their other engine lines like the LEAP, the GE9X engine for Boeing’s new 777X widebody jet, and military programs. The new approach would not only allow GE to produce the part in-house, but also to reduce supplier expenses. Aircraft engineering . For example, I think Rolls-Royce makes the best-looking fans, so there's some resemblance there... By the way, this model was featured on SolidSmack. Says one of the engineers, Dario Mantegazza, about 3D printing: “You have the ultimate manufacturing freedom.”. This is an engineer’s dream." GE Aviation is a world-leading provider of aircraft engines, systems and avionics. GE engineers 3D print mini jet engine, then power it to 33,000 RPMs Printing your own mechanical parts or toys is really easy, not to mention fun, using a 3-D printer. As a result, more than a third of the engine is 3D-printed. At GE, we rise to the challenge of building a world that works. A culture of integrity, compliance, safety, and respect for human rights, while reducing our environmental footprint. GE Additive Print Services Center is a full-scale, certified AS9100/ISO9001 additive printing and post-processing facility. He says that when GE acquired Avio Aero in 2013, “it was really fortunate because everything accelerated after that.”. To move faster, the team decided to print the bracket from a cobalt-chrome alloy — rather than the original nickel-based superalloy, Inconel 625 — because the FAA already certified it for use inside engines. Our technology, global network, and exceptional team is fueled by a mission—building a world that works. Access GE’s recent and historic Annual Reports and accompanying materials. By embracing diverse teams and perspectives, we are better equipped to build a world that works. The designers reduced 855 separate parts down to just 12. We wanted to promote 3D printing to potential customers and they were all coming here.”, That gamble required access to 3D printers, which Avio Aero obtained by partnering with ProtoCast, an Italian 3D-printing pioneer based in a workshop a short drive from Cameri. That created some hand-wringing. GE Aviation Auburn currently operates more than 40 metal 3D printers for the purpose of part production. Voices is a network for GE’s US supporters interested in the company’s impact in their communities and in issues that impact the company. Call it the little engine that could. Every two weeks, engineers pitch their ideas to this diverse body, which includes employees from GE Aviation’s supply chain, engineering and engine product lines. “It took time for it to sink in, before we realized that this is exactly what additive can be used for, to demonstrate its speed and low cost.”. Image credit: Adam Senatori for GE Reports “We called it ‘the submarine’ because it was so narrow you couldn’t walk past the people working with the machines.”. Access the latest press releases, media contacts, and press tools. They selected Concept Laser’s M2 printer, a fast, midsize machine that uses a pair of lasers to print four brackets at a time. Explore GE’s recent and historic SEC filings. GE's dedicated team, leading technology, and global reach and capabilities help the world work more efficiently, reliably, and safely. This week GE released this great GIF of its 1,300-horsepower advanced turboprop (ATP) engine in which more than one-third of … Accomplished leaders building GE’s legacy. “I like to get my hands dirty and get to understand the inner working of the machine, rather than just churning out hardware,” he says. Learn more about our culture, businesses, and life at GE. GE Aviation was developing its own 3D printing program near its headquarters in Cincinnati. “If it has only 50 percent of the weight of the nickel alloys you’ve got to believe this is here to stay.”, GE cast the blades in a foundry, but Avio Aero, which wanted to go after the emerging TiAl market, bet on 3D printing. The size of a walnut, this … GE Aviation plans to begin mass-producing the GEnx parts this month at its factory in Auburn, Alabama. 3D printed aircraft component . Tune in or catch up on GE’s latest investor events and reports. Additive ManufacturingAerospace3D printingGE. Commercializing GE’s technology and IP to accelerate growth and achieve market differentiation. The GE90 is one of the world’s most powerful jet engines. Last year, GE Additive and GE Aviation proposed a collaborative metal additive manufacturing program with the U.S. Air Force to accelerate the adoption of AM for spare parts. They started by focusing on individual machines, but in the future, they will feed the data into the cloud, monitor the parameters across a whole fleet of printers and look for patterns that will allow them to spot potential problems early. Our proprietary process optimizes every aspect of aerospace development and enables faster, more frequent, and lower cost access to space. The engineers from ATC and Auburn spent the spring collaborating and comparing notes so that Auburn will be ready to start cranking out the brackets. The company has completed testing of a demonstrator engine on which the ATP will be based that is made from more than 35 percent 3D-printed parts. We’re continuing to do all we can to support our customers and employees during this unprecedented time. GE Aviation is a world-leading provider of aircraft engines, systems and avionics. “The reason we did this project was because it represented several firsts for us,” says Eric Gatlin, a general manager for GE Aviation’s additive integrated product team. 3D printing and dozens of other new technologies used for the first time in a civilian turboprop engine allowed the team to combine 855 separate components into just 12, shave off more than 100 pounds in weight, improve fuel burn by as much as 20 percent, give it 10 percent more power and simplify maintenance. Together with our customers, we’re proving that no one is ever limited to only affordable, reliable, or sustainable energy. The part (seen here) was a sensor housing for the jet engine. Itemlive.com GE Sends First T408 to Navy 3D Printing Industry Boeing 777X: GE9X engines with 300 3D printed parts powers largest twin-engine jetliner in first flight The first GEnx engines used brackets made with traditional methods such as milling. The blades from Cameri are already working inside the first GE9X engines, which GE started testing last year. GE's innovation engine where ideas become reality to create a better world and deliver differentiated tech across the company's industrial portfolio. The goal is to help organizations adopt additive manufacturing technology faster by offering the ability to take parts from an idea to production. GE Aviation acquired Avio Aero in 2013 and developed the GE9X engine for Boeing’s next-generation 777X jets. The submarine, however, had a secret weapon: a powerful Arcam printer that print parts from TiAl powder. Explore a timeline of GE technologies that have spurred transformation across the world. “Fundamental engineering principles still apply. “The Lockheed plant made the town become very visible among aerospace companies. Discover how our people & technology are solving global issues, improving lives, and changing industries. “This factory has helped us understand what the art of the possible is with additive manufacturing,” said David Joyce, president and CEO of GE Aviation. Boeing 777X: GE9X engines with 300 3D printed parts powers largest twin-engine jetliner in first flight GE Aviation has announced that American multinational aerospace giant Boeing has … Contact information for general inquiries and feedback. Learn more about our culture, businesses, and life at GE. Read the results of the 2020 GE Global Innovation Barometer, titled “Pride and Protectionism: A Quest for Innovation Agency.”. Access the latest press releases, media contacts, and press tools. Image credit: GE Aviation. Also known as additive manufacturing, it has opened new paths for designers to create custom shapes that were previously too expensive or downright impossible to make. A single machine can simultaneously print six turbine blades directly from a computer file by using a powerful 3-kilowatt electron beam. GE’s new LEAP and GE9x jet engines are among the most ambitious programs in the company’s history. Creating the energy technologies of the future and improving the power networks that we depend on today. When it comes to flying, he says, every ounce counts. “A lot of the things we do here, we are doing for the very first time. As a senior engineer for additive design at GE Aviation’s Additive Technology Center (ATC) in Cincinnati, in 2016 he helped bring to mass production a 3D-printed fuel nozzle that efficiently sprays fuel inside the LEAP jet engine. If left untreated, smoke could deposit soot into the tiny pools of molten metal created by the lasers and alter the density of the part — but also disperse the laser beam and make it less sharp, like sun rays filtering through morning fog. Over the last 10 months, they've developed a new process to mass-print a much larger part for a version of the GEnx jet engine that powers the latest generation of Boeing 747s. That’s when a group of designers working at the ATC came up with a clever solution: fitting all the parts like interlocking fingers onto a single “build plate” the size of an average computer screen. The engine in question is actually a 3D-printed model, designed by GE. To do so, the team also had to “production-proof” the new line of printers for the part. “We were being charged a significant amount for these parts,” Gatlin says. Learn about governance at GE, including the latest Proxy Statement and information about the GE Board of Directors. “It’s a highly collaborative process,” Martinello says. We’re continuing to do all we can to support our customers and employees during this unprecedented time. The Cameri plant employs eight specialized hourly workers feeding the machines with powder, removing and cleaning the printed parts, and doing maintenance. At GE, we rise to the challenge of building a world that works. Offering a suite of products to help unlock the full potential of additive manufacturing. As a senior engineer for additive design at GE Aviation’s Additive Technology Center (ATC) in Cincinnati, in 2016 he helped bring to mass production a 3D-printed fuel nozzle that efficiently sprays fuel inside the LEAP jet engine. He says this is especially important in aviation because of tight FAA regulations due to the importance of safety and quality in air travel. The two … GE's innovation engine where ideas become reality to create a better world and deliver differentiated tech across the company's industrial portfolio. what the prefix means in different engine families of GE waukesha.ATGL,APG,VHP,VGF,VSG,275 GL. According to GE … Explore a timeline of GE technologies that have spurred transformation across the world. The Blade Runners: This Factory Is 3D Printing ... - GE.com Electric motors & generators engineering . “We want to have everything quantified and take variation out of the process,” Martinello says. Ignition, Combustion and Detonation engineering . That’s a big deal given that fuel accounts for about 19 percent of an airline’s operating costs. They’ve identified more than 100 components that could be printed. Learn how we’re delivering on our priorities. Of those, one-third are new products like the Catalyst engine, but the rest involve redesigning existing parts like the bracket — a huge new market for additive manufacturing. Explore the latest stories, news, downloads, and press tools. Above: GE Aviation's Additive Technology Center in Cincinnati might easily be the world’s largest and most advanced 3D-printing and development center. These and other new materials and technologies will help make the engine 10 percent more fuel-efficient than its predecessor, the GE90. The group, based in the U.S. and also in Germany, would get together every day on a 7:30 a.m. conference call to track their progress and lay out their next steps. Running more experiments, he also learned that preheating the powder before printing removed much of the residual stress from the finished parts. Answers to popular and relevant inquiries. We build intelligent devices, data analytics, applications and services to enable healthcare practitioners to deliver care more efficiently and with better outcomes. For the last four years GE has been manufacturing 3D printed fuel nozzles for the A320's jet engine. It was developing a 3D printed fuel nozzle for a new jet engine called the LEAP and working with Greg Morris, the founder of Morris Technologies and another leading light in the additive movement. Now there's only one piece—and it's five times stronger. Martinello knows this as well as anyone. GENERAL ELECTRIC, 763, DC TRACTION MOTOR, LOCOMOTIVE TRACTON MOTOR. Back in Cincinnati, Gatlin, Martinello, Brandel and their colleagues are already working on their next projects. More than a third of the ATP is 3D-printed from advanced alloys. Getting the part ready for printing was another riddle. “I’ve been doing this for three years now, but I still have to take a step back and remind myself what it is we are trying to do and why,” he says. GE now prints 600 of them per week as a single piece. A culture of integrity, compliance, safety, and respect for human rights, while reducing our environmental footprint. By then, Avio Aero bought ProtoCast and signed an exclusive agreement with Arcam to acquire a set number of the modified machines. GE has received orders for 1,658 LEAP and other engines, which can each include up to 19 3D printed fuel nozzles. Access important shareholder information. GE’s LEAP engine with 3D printed parts helps rake in $31 B at Paris Air Show. And just across from the plant’s runway stands another futuristic manufacturing gem: Avio Aero’s 3D-printing factory making sleek turbine blades for the GE9X, the world’s largest jet engine, which took its maiden flight last week. One of the team’s tasks early on was making sure that brackets coming out of the machines were of identical quality. 3D printing is still so new that Martinello, who is 37, is often learning on the job. “In the design of jet engines, complexity used to be expensive," Ehteshami says. Image credit: Tomas Kellner for GE Reports. June 26, 2017 Staff. Top: Brandel (left) and Martinello (right) hold in their hands 3D-printed brackets for the GEnx-2B engine. Access GE’s recent and historic Annual Reports and accompanying materials. “We ran a lot of experiments to get the job right.” Tune in or catch up on GE’s latest investor events and reports. “For us to step up and bet the engine on this technology is a big deal,” Robert Schafrik, then GE Aviation’s materials and process engineering general manager, told FlightGlobal. “But as soon as you have to print thousands of copies of the same part consistently, you are in a territory that’s both similar to traditional manufacturing, but also more complex than anything that we’ve had before.”. Commercializing GE’s technology and IP to accelerate growth and achieve market differentiation. The size of a walnut, this wickedly complex metal part was previously made from 20 components. Additive manufacturing is still a young industry, albeit one going through a growth spurt. “When the project first came to us, we said, ‘This is an oddball, this is an outlier,'” Gatlin says. Working in a parallel track, a team of engineers was readying the Concept Laser machine for mass production. Starting with rockets, our Stargate factory vertically integrates robotics, software, and patented 3D printing technologies to digitize manufacturing. It already was a single piece of metal, and because it’s already inside a working engine, the GEnx first flew in 2010, the designers had to stay close to drawings approved by the FAA. Avio Aero started exploring 3D printing more than a decade ago. At the time, word got out that GE Aviation had used TiAl blades inside the GEnx jet engine it was developing for Boeing’s Dreamliner. “Minor tweaks here and there are OK in the development phase, but when you get into production, everything has to be locked down," says Danny Brandel, a lead manufacturing engineer at the ATC and a member of the team. The beam “grows” the blades, which are 40 centimeters long, by welding together thin layers of titanium aluminide powder, one after another. Together with our customers, we’re proving that no one is ever limited to only affordable, reliable, or sustainable energy. The 3D-printed blades spin inside the engine at 2,500 times per minute and face searing heat and titanic forces. The blades were cracking when Abrate and the team tried to separate them from the platform on which they were printed. Engineers working on the ATP are planning to run it for the first time in a special test cell in Prague, Czech Republic, later this year. “When you are printing it, it’s hard to tell whether it’s one part or four parts, but when you cut them off the plate, they separate and you have an aircraft’s worth of brackets in one build.”. The aluminium manifold inlet, 3D printed on a Concept Laser X LINE 2000R from GE Additive, took five days to complete. But in order to make the approach economical, they had to print four brackets at a time. Jet engine designers love this strong, heat-resistant wonder material, also known as TiAl. The company is already using individual 3D-printed fuel nozzles and other parts in its jet engines and gas turbines. Explore the latest stories, news, downloads, and press tools. “Air flow is pretty critical in terms of getting parts with good internal and external quality,” Brandel says. Voices is a network for GE’s US supporters interested in the company’s impact in their communities and in issues that impact the company. The fist-sized T25 housing for a compressor inlet temperature sensor was fabricated by GE Aviation and will be retrofitted to over 400 GE90-94B jet engines on Boeing 777 aircraft. Read on to see how. 3D printing has rightfully gotten a lot of buzz because of the marvels it can do. The list includes printing parameters, but also heat treatment and inspection steps. “We just had to machine some bolt holes and some clevis pins and we were done,” he says. We build intelligent devices, data analytics, applications and services to enable healthcare practitioners to deliver care more efficiently and with better outcomes. Accomplished leaders building GE’s legacy. But early runs with ProtoCast’s laser-powered printers failed. “But we had positive experiences with 3D printing on a military project.”, The company decided to take advantage of the nearby Joint Strike Fighter assembly plant and set up its additive manufacturing shop nearby. Fortunately for GE, the company now owns two of the largest metal 3D printer … Creating the energy technologies of the future and improving the power networks that we depend on today. GE's dedicated team, leading technology, and global reach and capabilities help the world work more efficiently, reliably, and safely. Answers to popular and relevant inquiries. I think that breeds a certain amount of excitement, a certain amount of energy, and requires a certain culture.” Image credit: GE Aviation. First, members of the Additive Global Management team, who decide what to print, had to agree on whether they even wanted to make the part. GE Aviation plans to mass-produce them on Concept Laser 3D printers. Abrate reached out to Arcam to tweak the machine’s design, make the powder layer thicker and speed up the printing process. We connect capital to infrastructure and deliver innovative financial solutions that help make the world work better. Our technology, global network, and exceptional team is fueled by a mission—building a world that works. Read More Learn how we’re delivering on our priorities. For example, they took a system designed to air out the smoke produced when the powerful lasers hit and melt the layers of powder into the desired shape, and gave it more power. Mohammad Ehteshami, who launched GE Additive, expects the industry to grow from $7 billion today to $80 billion in a decade. GE has been working on the engine for the last three years. What if a fix was as simple as whipping up your own 3D printed parts? I designed the whole engine from scratch with visual cues to certain existing engines. “There’s no part that just comes off a printer and goes straight into the engine,” Gatlin says. Last year, a team of engineers at GE Aviation’s Additive Technology Center built an almost entirely 3D printed miniature jet engine — a backpack-size powerhouse that hits 33,000 rotations per minute. This is the first time GE has designed a mass-production process for a line of its own printers made by Concept Laser, a German engineering company it acquired in 2016. GE plans to produce 100,000 3D-printed components for the next-generation GE9X and Leap models Courtesy of GE Aviation Discover how our people & technology are solving global issues, improving lives, and changing industries. Learn about governance at GE, including the latest Proxy Statement and information about the GE Board of Directors. Twenty parts were once machined together to construct part of the CFM Leap engine. We connect capital to infrastructure and deliver innovative financial solutions that help make the world work better. It’s just a new tool that you have at your disposal. Cameri is the home of the only final assembly plant outside the United States for Lockheed Martin’s F-35B Joint Strike Fighter, a stealthy jet that can take off and land vertically. Transforming how industry solves its toughest challenges by bringing simplicity, speed and scale to digital transformation. “They were already convinced,” Abrate says. “When the GEnx program kicked off, they just hogged the brackets out of a big block of metal,” Martinello says. Read the latest GE financial news releases and stories. Read the results of the 2020 GE Global Innovation Barometer, titled “Pride and Protectionism: A Quest for Innovation Agency.”. Got broken things that need a little TLC? We’re deeply proud of GE employees around the world rising to the challenge. More than a third of the ATP engine’s parts will be crafted in 3D printers. “It was really a garage,” Abrate recalls. In 2016, GE  took a majority stake in Arcam and launched GE Additive, a new business focusing on additive manufacturing technologies like 3D printing. That's the step that GE Aviation took when it recently fired up a simple jet engine made entirely of 3D-printed parts in a test stand normally reserved for commercial jet power plants. But take a short ride through the rolling fields of the fertile Po Valley that surround it and you’ll discover a startling contrast. “We could see how difficult it was to make these blades,” Abrate says. A GEnx engine on a test stand in Peebles, Ohio. But  TiAl is also very brittle. The technology's potential is enormous, but GE engineer Peter Martinello offers a dose of perspective. “It’s our first program we certified on a Concept Laser machine, and it’s also the first project we’ve taken from design to production in less than 10 months.”. The Northern Italian town of Cameri could be easily mistaken for a quiet farming commune. “By the time you had the finished product, you cut away more than half of it.” The team realized that by 3D-printing the part, they would be able to reduce as much as 90 percent of the waste. Above: The 3D printed nozzle combined all 20 parts into a single unit, but it also weighed 25 percent less. Access important shareholder information. For more than 25 years, our focus has been on bringing your ideas to life faster than you thought “This is true if you have to print just one part,” he says. Contact information for general inquiries and feedback. There are also nine manufacturing engineers, who keep improving the production process. Several parts benefit from the use of custom supports. Brandel and his colleagues spent several months making sure the machines were ready for prime time. But additive allows you to get sophisticated and reduces costs at the same time. It’s about understanding what it can do, and how it can improve your designs.”, https://www.facebook.com/GE/videos/10160864544500422/. A few weeks ago General Electric announced that the FAA (U.S. Federal Aviation Administration) cleared their first 3D printed part to fly. By embracing diverse teams and perspectives, we are better equipped to build a world that works. When Avio Aero showed GE what it was doing with the wonder metal, the American company quickly grasped the magnitude of the breakthrough. A model of a 2-spool high bypass turbofan. “It’s not hard to walk into this building every morning and go to work,” says Eric Gatlin, a general manager for GE Aviation focusing on additive manufacturing. Sixty other designs are being perfected, some reducing the number of parts … GE also opened additive manufacturing labs in the U.S. focusing on the technology. The printed plane engine has arrived. It weighs 50 percent less than the metal alloys typically used in aviation. Explore a career with us. The 3D printing factory, which looks like a blue and gray jewel box of steel and glass from the outside, holds 20 black, wardrobe-sized 3D printers, made by Arcam. FORECAST 3D has been providing 3D printing & custom manufacturing to our customers in a variety of industries ranging from healthcare to aerospace, consumer goods to design. The FAA recently cleared the first 3D printed part in a commercial jet engine from GE. The first GE jet engine to actually take flight while using a 3-D-printed part is the GE90. “It looks like one of those woodblock puzzles, where all the pieces fit together,” Gatlin says. Challenge of building a world that works typically used in Aviation because tight... 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