GKN Aerospace, global industry experts in advanced aerostructures and engine systems, and Pratt & Whitney, a world leader in aircraft propulsion, have signed a Technology Development Agreement to explore additive manufacturing of large structural components for the F135 engine powering the F-35 Lightning II. Supported by the Norwegian Defence Materiel Agency, the joint development program will evaluate the feasibility of producing a full-scale engine case using additive manufacturing while maintaining compatibility and interchangeability with the current engine design. The partners expect to complete their first large-scale demonstrator component in 2027 and are targeting certification of the finished product by the end of 2028.

Development work will be led from the GKN Aerospace engine facility in Kongsberg, Norway, using the company’s laser-directed energy deposition with wire, or L-DED-w, process. GKN Aerospace has developed and matured this additive manufacturing technology over several years, including investments to expand its additive capabilities in Kongsberg and across its wider manufacturing network.

GKN Aerospace in-house materials testing demonstration supporting additive manufacturing development for large aircraft engine structures. | Aerospace Technology Monthly

An in-house materials testing demonstration highlights GKN Aerospace capabilities supporting the development of large additively manufactured aero-engine structures.

Unlike additive processes developed primarily for smaller components, the program will examine whether L-DED-w can meet the manufacturing, materials and performance requirements of a large, high-performance military engine structure. Producing a full-scale case that remains interchangeable with the current component will require the manufacturing process to satisfy established dimensional, material and interface requirements while supporting future certification. The demonstrator is expected to be among the first additively manufactured engine structures of its size developed for a military engine application. The program will provide GKN Aerospace and Pratt & Whitney with the manufacturing and test data needed to evaluate the technology at a scale and level of complexity relevant to future production.

Additive manufacturing could strengthen aerospace supply chains and improve production processes by reducing lead times, lowering material use and increasing overall efficiency. The collaboration will evaluate these potential benefits within the quality, repeatability and certification requirements of military aircraft propulsion.

“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,” said Sébastien Aknouche, Senior Vice President, GKN Aerospace.

The agreement builds on the companies’ existing work across commercial and military aircraft engine programs. GKN Aerospace already produces additively manufactured engine structures for commercial aircraft applications and has advanced load-bearing components into serial production, providing an established foundation for assessing the technology on larger and more demanding F135 structures.

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

The F135 powers all three variants of the F-35 Lightning II. Extending additive manufacturing to large structural engine cases could support future production readiness and supply-chain resilience while maintaining commonality with the propulsion system’s existing configuration.

About GKN Aerospace

GKN Aerospace is a global Tier 1 aerospace supplier of airframe and engine structures, landing gear, electrical interconnection systems, transparencies and aftermarket services. The company supplies technologies for commercial, military and advanced air mobility platforms and has worked in additive manufacturing and additive fabrication for approximately two decades. Its additively manufactured components are used on multiple aircraft and engine platforms, including the Airbus A220 and Embraer E195-E2. For more information, please click here.

About Pratt & Whitney

Pratt & Whitney, an RTX business, is a world leader in the design, manufacture and service of aircraft engines and auxiliary power units for commercial, military and civil aviation customers. Founded in 1925, the company develops and supports propulsion technologies through a global network of engineering, manufacturing, maintenance, repair and overhaul facilities. Pratt & Whitney supports more than 90,000 engines in service worldwide. To learn more, please click here.

Source/Photo Credit: GKN Aerospace

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Molly Bakewell Chamberlin
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