US Air Force and GE’s collaboration on metal AM reaches first milestone

In mid-2019, GE Additive and GE Aviation approached the US Air Force to propose a metal additive collaboration program to address its specific sustainment, readiness and affordability needs. It’s the US Air Force’s Rapid Sustainment Office (RSO) that is in charge of the operation and sustainment of its fleet of aircraft. Given the number of aircraft soon entering their sixth decade of service, difficulties in sourcing and producing spare parts could represent a significant risk. This is where 3D printing technologies come in, enabling the production of unique, on-demand parts that meet the specific requirements of the aerospace industry.

GE has previous experience qualifying and certifying additively manufactured metal components that meet the commercial aviation sector’s rigorous regulatory requirements. Colonel Benjamin Boehm, director, AFLCMC/LP Propulsion Directorate, explains: “The collaborative effort between the US Air Force and GE shows great promise toward the adoption of metal 3D printed parts as an option to solve the US Air Force’s current and future sustainment challenges. This capability provides an alternate method to source parts for legacy propulsion systems throughout their life cycle.”

GE Aviation F110 engine | Credits: GE Additive

The benefits of metal additive manufacturing

The US Air Force and GE settled on a program based on a “spiral development” model that increases in complexity and scale with each phase. In this program, complexity involves moving from simpler part identification, progressing to part and family of parts consolidation and eventually tackling complex components and systems, such as common core heat exchangers. The key benefit of using additive manufacturing technologies in this case is the speed at which it is possible to develop these solutions.