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At the GE Power Services manufacturing site in Birr, Switzerland, his team recently used the Hamuel machine to not just repair blades, but also modify them for improved performance. GE Considers 3D Printing Turbine Blades for Next Generation Boeing 777X’s GE9X Engines . Read the results of the 2020 GE Global Innovation Barometer, titled “Pride and Protectionism: A Quest for Innovation Agency.”. Of the seven components and 304 parts being additively manufactured for the GE9X, all except the LPT blades and the heat exchanger are cobalt chromium alloy parts. You just can’t get the same results with parts made by traditional metal casting, Passmore says. Jet designers love TiAl because it’s light and strong — but until 3D printing became a realistic option, manufacturing with the material was difficult, requiring molding and expensive tools. The team's 3D printers make the parts by with lasers welding together thin layers of metal powder — in this case, a nickel superalloy. A prototype of a wind turbine base 3D printed from concrete. Bingo: a high-tech cooled part, which saves on pumped air. The expansion will allow Cameri to produce 60,000 turbine blades a year by 2023. Tune in or catch up on GE’s latest investor events and reports. A culture of integrity, compliance, safety, and respect for human rights, while reducing our environmental footprint. GE’s Cameri operations are indicative of the advances taking place in manufacturing today. Read the latest GE financial news releases and stories. Answers to popular and relevant inquiries. Discover how our people & technology are solving global issues, improving lives, and changing industries. The turbine was — and still is — the world’s most reliable and efficient gas turbine in its class. GE acquired a majority stake in Arcam last fall. Offering a suite of products to help unlock the full potential of additive manufacturing. The 3D-printed parts also boost the power capacity of the gas turbine, depending on its upgrade status, by up to 21 MW. Passmore's 3D-printed parts will soon be helping to keep the German capital warm. GE Aviation is a world-leading provider of aircraft engines, systems and avionics. Today GE unveiled a breakthrough process for 3D printing light-weight metal blades for jet engine turbines. Access the latest press releases, media contacts, and press tools. Tune in or catch up on GE’s latest investor events and reports. A 30% reduction in the weight of each of the GE9X turbine blades is contributing to a 10% increase in fuel efficiency compared with the GE90 engine that came before it, while the GE Additive team is keen to point out these critical and moving … Image credit: GE. But 3D printing gives engineers a new level of sophistication, and they can make heat shields with advanced internal air passages. According to GE, 3D … Creating the energy technologies of the future and improving the power networks that we depend on today. The printer works with microscopic precision and Passmore admits losing himself as he watches a turbine part growing slowly before his eyes. We’re deeply proud of GE employees around the world rising to the challenge. GE's innovation engine where ideas become reality to create a better world and deliver differentiated tech across the company's industrial portfolio. It follows the GE9X engine’s first test flight on a Boeing 777X aircraft earlier this year and represents a ‘key milestone’ for GE and Boeing alike. The parts help, MXL2 with Additively Manufactured Performance (AMP),". “These are big blades,” says Giorgio Abrate, general manager for engineering at Avio Aero. 3D PRINTING JET ENGINE BLADES The lush green fields near the town of Cameri in northern Italy hide an industrial secret: a futuristic factory that 3D prints 15-inch, sleek turbine blades for … In 2015 GE Aviation opened its Additive Technology Center near its headquarters in Cincinnati, where engineers from GE Aviation and GE Additive conceive, design and manufacture 3D-printed components for jets and other products, and also improve on 3D printers. “We aren’t crazy guys in white coats in a lab — these are real parts we’re using for the commercial upgrade of massive machines.”, He pauses, remembering again the first time he saw the 3D printers at work in Switzerland. Key features include a 133" diameter composite fan case and 16 composite fan blades; a next-generation 27:1 pressure ratio 11-stage high-pressure compressor; a third-generation twin annular pre-swirl (TAPS) combustor for greater efficiency and low emissions; and ceramic matrix composite (CMC) material in the combustor and turbine. We’re deeply proud of GE employees around the world rising to the challenge. The company expects to add another 16 Spectra H machines to the plant in the near future, followed by a possible replacement of the smaller A2X printers with the Spectra H. “Thanks to the expansion and these new machines, we will definitely be able to produce a larger number of blades,” said Avio Aero’s Marco Bozzola, who operates the machines at the plant. Our technology, global network, and exceptional team is fueled by a mission—building a world that works. Explore GE’s recent and historic SEC filings. Explore a timeline of GE technologies that have spurred transformation across the world. Learn how we’re delivering on our priorities. In order to receive FAA certification, the … Following a software blueprint designed by GE engineers, each printer builds several of the 40-centimeter-long blades at once, layer by layer, over the course of a couple days. I included these supports in the parts as … Making blades for an engine turbine typically involves casting them from red-hot alloys or pounding them out on massive forging machines. Low pressure turbine (LTP) blades 3D-printed from titanium aluminide (TiAl) for the GE9X engine. GE Aviation acquired Avio Aero in 2013 and developed the GE9X engine for Boeing’s next-generation 777X jets. — David Joyce, president and CEO, GE Aviation 1. 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. The greater size allows the facility to host a total of 35 Arcam machines: 31 A2X printers and four Spectra H machines, which are larger and produce more parts at once. We’re continuing to do all we can to support our customers and employees during this unprecedented time. Commercializing GE’s technology and IP to accelerate growth and achieve market differentiation. “It’s just hypnotic,” he says. Mantegazza and his colleagues are using it to print blades for the low-pressure turbine of the GE9X jet engine, the largest jet engine ever built. Several parts benefit from the use of custom supports. The 3D printed fuel nozzle inside the GE9X was 3D printed … Now, he describes how the application of metal 3D printing to existing turbine blades has proceeded even further under GE. Access important shareholder information. The printers were built by Arcam, a company GE acquired in 2016 and folded inside its GE Additive business. In the next few years, the group hopes to finish a full-scale wind turbine prototype with 3D printed base, a production printer, and enough materials to scale. Access the latest press releases, media contacts, and press tools. Explore GE’s recent and historic SEC filings. It was easy to understand why. Access GE’s recent and historic Annual Reports and accompanying materials. We’re continuing to do all we can to support our customers and employees during this unprecedented time. Contact information for general inquiries and feedback. 3D printing in the GEnx. But this cooling air has a cost — the energy used to compress this air drastically reduces the turbine’s efficiency. Get ready to be blown away by these cool wind-powered prints! I designed the whole engine from scratch with visual cues to certain existing engines. Arcam’s 3D printers solve those problems by welding metallic powder with an electron beam at temperatures up to 1,000 degrees Celsius. It’s a startling contrast, then, that less than a mile from the center of this village sits a major hub of aerospace innovation, anchored by one of largest 3D-printing factories in the world. Power giant Vattenfall will boost the power capacity of its turbine at its iconic district heating plant in Mitte, Berlin, by 21 MW using the parts. It’s a critical part in the front section of the turbine that sees its hottest temperatures — over 1,200 degrees Celsius. At more than 11 feet in diameter, the engine is about the width of an entire Boeing 737. Learn more about our culture, businesses, and life at GE. Later in 2019, it was revealed that GE Aviation had added 27 Arcam electron beam melting (EBM) machines to produce titanium aluminide (TiAl) blades for the GE9X engine. The 3D-printed blades spin inside the engine at 2,500 times per minute and face searing heat and titanic forces. Answers to popular and relevant inquiries. Operated by Avio Aero, a GE Aviation company, the plant makes the arm-sized blades for the GE9X engine, the world’s largest jet engine. Discover how our people & technology are solving global issues, improving lives, and changing industries. The engineers fix the freshly printed parts into the turbine — and that’s when the magic happens. GE hopes to 3D print the base of a turbine wherever they want to place it, so that they won’t need to haul around such a gigantic hunk of concrete or steel. To meet rising demand, GE recently expanded Cameri’s manufacturing space by 6,500 square feet to … Infill design of a prototype 3D printed wind turbine base [Source: COBOD] With a 200m tower, blades could be theoretically up to 200m (less ground safety clearance) in length, generating a corresponding efficiency increase in the turbine’s electrical output. At GE, we rise to the challenge of building a world that works. GE Aviation’s GE9X engine, which is equipped with more than 200 metal additively manufactured turbine blades, has received certification from the Federal Aviation Administration (FAA).. In other words, the blades of each turbine can be optimized for the individual location, wind, and turbulence patterns at each and every location in the farm. Learn all about how to print your very own 3D printed wind turbine. Contact information for general inquiries and feedback. Accomplished leaders building GE’s legacy. GE estimates that this new upgrade, the company calls it "MXL2 with Additively Manufactured Performance (AMP)," can help power producers save up to $2 million in fuel annually. Such uses vindicate the technology, Passmore says. GE’s Power and Healthcare divisions are also exploring 3D printing, as are many of GE Additive’s customers, who use the technology to build everything from bicycles to skull implants. To meet rising demand, GE recently expanded Cameri’s manufacturing space by 6,500 square feet to 26,000 square feet. Access GE’s recent and historic Annual Reports and accompanying materials. Explore the latest stories, news, downloads, and press tools. Transforming how industry solves its toughest challenges by bringing simplicity, speed and scale to digital transformation. Photo via GE Additive. Avio Aero ramped up to continuous production at Cameri this spring. “We’re doing whole rows in-house in one hit,” Passmore 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. A model of a 2-spool high bypass turbofan. The turbine was — and still is — the world’s most reliable and efficient gas turbine in its class. Foot-long low pressure turbine blades in the GE9X are also 3D printed, reducing overall engine weight and maximizing size and power. The turbines are not just heavyweight generators that keep the lights on — they also power energy-hungry aluminum smelters worldwide, and deliver the heat for district heating networks, which keep radiators and water hot in chilly northern and eastern Europe. Derived from the General Electric GE90 with a larger fan, … An Arcam 3D printer at GE's Center for Additive Technologies Advancement. We build intelligent devices, data analytics, applications and services to enable healthcare practitioners to deliver care more efficiently and with better outcomes. Commercializing GE’s technology and IP to accelerate growth and achieve market differentiation. A team from GE Power's Advanced Manufacturing Works is now 3D printing high-tech parts in Switzerland that take the turbine's performance even higher. A culture of integrity, compliance, safety, and respect for human rights, while reducing our environmental footprint. GE's dedicated team, leading technology, and global reach and capabilities help the world work more efficiently, reliably, and safely. Now, he describes how the application of metal 3D printing to existing turbine blades has proceeded even farther under GE. 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. They use electron beams to weld together millions of grains of fine powdered metal, one hair-thin layer after another, to form some of the jet engine’s most durable parts. 3D printing allows engineers to sculpt intricate configurations that are impossible to achieve in a foundry. Now imagine a whole row of 40 heat shields in one turbine, and you can see how efficiency gains stack up. Vattenfall has already been running 3D-printed trial parts in the engine for three years. It also opens up the potential for additional revenue of up to $3 million per year. running 3D-printed trial parts in the engine for three years. “We can also count on greater mechanical and electronic stability, and we can even consider new geometries.”. Transforming how industry solves its toughest challenges by bringing simplicity, speed and scale to digital transformation. GE's innovation engine where ideas become reality to create a better world and deliver differentiated tech across the company's industrial portfolio. GE's dedicated team, leading technology, and global reach and capabilities help the world work more efficiently, reliably, and safely. are introducing custom 3D-printed glasses [1]. Using the GEnx testing engine, GE assessed new additive manufactured blades for the engine’s turbine. GE will design the wind turbines, COBOD will build the 3D printer, and LafargeHolcim will make a proprietary blend of concrete for the job. Together with our customers, we’re proving that no one is ever limited to only affordable, reliable, or sustainable energy. Cast heat shields survive in the engine by being fed lots of pressurized cooling air. In 2017, the company used 3D printing to develop and test functional prototypes of gas turbine blades – small parts assembled around the periphery of a turbine rotor to guide the gas flow. Developed by engineers at the Italian aerospace company Avio and Sweden's Arcam. The goal is to help organizations adopt additive manufacturing technology faster by offering the ability to take parts from an idea to production. But it is the first time anyone has used a 3D-printed, full-size part directly in a gas turbine upgrade. Learn about governance at GE, including the latest Proxy Statement and information about the GE Board of Directors. This isn’t the first time that large 3D-printed objects have been used in engines. Explore the latest stories, news, downloads, and press tools. GT13E2. We connect capital to infrastructure and deliver innovative financial solutions that help make the world work better. GE Additive Print Services Center is a full-scale, certified AS9100/ISO9001 additive printing and post-processing facility. You just can’t get the same results with parts made by traditional metal casting, Passmore says. Siemens, EOS and Materials Solutions challenge existing technologies to advance and truly industrialize 3D printing. Explore a career with us. The beam enables the machines to print faster and fuse layers as thick at 100 microns, twice the width of what a laser can print. Learn how we’re delivering on our priorities. Together with our customers, we’re proving that no one is ever limited to only affordable, reliable, or sustainable energy. But it is the first time anyone has used a 3D-printed, full-size part directly in a gas turbine upgrade. Explore a timeline of GE technologies that have spurred transformation across the world. Access important shareholder information. Read the latest GE financial news releases and stories. GE engineers had again squeezed new efficiencies and record reliability out of the overachieving machine known in the power industry as the GT13E2. Additive manufacturing is In the wind-power industry, this could mean optimized wind-turbine blades per tower in a wind farm. Following a software blueprint designed by GE engineers, each printer builds several of the 40-centimeter-long blades at once, layer by layer, over the course of a couple days. “When I saw the parts coming out of the machine, I thought, ‘Wow — we have arrived.’”, enough to supply with electricity the equivalent of. Nestled in the rolling hills of the Po Valley, the small town of Cameri looks like a postcard Italian village, complete with a classic piazza surrounded by traditional-style buildings and a church. The scalability and repeatability of 3D printing is also a boon. At GE, we rise to the challenge of building a world that works. But it turns out that the engineers were only getting started. By embracing diverse teams and perspectives, we are better equipped to build a world that works. Creating the energy technologies of the future and improving the power networks that we depend on today. The GE9X engine will be in the 100,000 lb. “Along came additive manufacturing — or 3D printing — and it changed everything,” Passmore says. GE Aviation is a world-leading provider of aircraft engines, systems and avionics. We build intelligent devices, data analytics, applications and services to enable healthcare practitioners to deliver care more efficiently and with better outcomes. is the first time anyone has used a 3D-printed, full-size part directly in a gas turbine upgrade. Take a turbine’s stator heat shield, a paperback-size piece of metal that protects the engine’s casings. According to Siemens, 3D printing blade prototypes reduced the development and validation time for the component from two years to just two months . GE will design the wind turbines, COBOD will build the 3D printer, and LafargeHolcim will make a proprietary blend of concrete for the job. The General Electric GE9X is a high-bypass turbofan developed by GE Aviation exclusively for the Boeing 777X.It first ran on ground in April 2016 and first flew on March 13, 2018; it powered the 777-9's maiden flight in early 2020. One of the innovations involves making the blades from a wonder material called titanium aluminide (TiAl). thrust class. This isn’t the first time that large 3D-printed objects have been used in engines. The GE9X engine had its maiden flight last year, and the Boeing jets they’re going to power are expected to begin deliveries to airlines next year. Engineers can print several parts simultaneously — up to 20 at a time — rather than casting them one by one. Learn about governance at GE, including the latest Proxy Statement and information about the GE Board of Directors. GE Additive’s Arcam EBM A2X machines are capable of producing six blades per batch, while the Spectra H system can produce up to ten blades in around the same time. At the GE Power Services manufacturing site in Birr, Switzerland, his team recently used the Hamuel machine to not just repair blades, but also modify them for improved performance. Read the results of the 2020 GE Global Innovation Barometer, titled “Pride and Protectionism: A Quest for Innovation Agency.”. GE will develop 3D-printed bases for its wind turbines, allowing them to generate more energy as they reach new heights. We connect capital to infrastructure and deliver innovative financial solutions that help make the world work better. Heat resistant titanium aluminide powder + an electron beam inside Avio Aero factory = 3D printed turbine blades for the largest jet engine in the world. It received its Federal Aviation Administration (FAA) type certificate on September 25. The Blade Runners: This Factory Is 3D Printing Turbine Parts For The World's Largest Jet Engine March 20, 2018 GE Additive launches Orthopaedic Validation Consultancy at … GE developed the GE9X engine for Boeing’s next-generation 777X jet. Explore a career with us. Our technology, global network, and exceptional team is fueled by a mission—building a world that works. By embracing diverse teams and perspectives, we are better equipped to build a world that works. The machine uses an electron beam, which is more powerful than laser. For instance, GE engineers are also 3D-printing sleek turbine blades for the GE9X, the world’s largest jet engine, which took its maiden flight in March. According to GE Aviation, the GEnx is the fastest-selling, high-thrust jet engine within the company’s history, with over 1,600 engines on order. One of those blades is being swung repeatedly in the hand of Arcam’s General Manager Karl Lindblom to prove how light the component is. At Cameri, though, it’s a quiet, controlled process that takes place inside humming, refrigerator-sized 3D printers that stand in neat rows inside a cavernous hall the size of a warehouse. For instance, GE engineers are also 3D-printing sleek turbine blades for the GE9X, the world’s largest jet engine, which took its maiden flight in March. 3D printing was seen as a very attractive option for large products such as wind turbine blades, which are very labor intensive, primarily done by hand labor of depositing large amounts of composite material, making the molds themselves quite costly and timely to make. Offering a suite of products to help unlock the full potential of additive manufacturing. A series of innovative designs, however, means that despite its physical size, the GE9X improves fuel efficiency by 10% over the GE90 engine, which powers most current 777 planes. The Arcam machines use an electron gun to accelerate the beam until it’s several times more powerful than lasers currently used for printing … Learn more about our culture, businesses, and life at GE. Additive manufacturing is still a young industry, albeit one that’s growing rapidly. The alloy also tended to come out brittle. Accomplished leaders building GE’s legacy. Been used in engines wind farm Center for additive technologies Advancement ideas become to. Three years with visual cues to certain existing engines latest press releases, contacts. Of additive manufacturing s efficiency parts made by traditional metal casting, Passmore says engineers print... For 3D printing is also a boon at Cameri this spring that no one is ever limited to only,... 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