This advanced project saw an integrated effort between Pratt & Whitney’s engineering experts, its repair specialist Component Aerospace Singapore, and the Land Systems arm of ST Engineering. The 3D-printed aero-engine component taps into the production-level 3D capabilities of ST Engineering, and the strong domain knowledge in metal printing via a controlled process put into operation by Pratt & Whitney. This 3D-printed part will first be used in a fuel system on one of Pratt & Whitney’s engine models. The solution offers the added advantage of reducing dependency on current material supply from conventional fabrication processes, such as forging and casting.
“Thanks to the out-of-the-box thinking by our employees at Component Aerospace Singapore, we are now another step closer to scaling this technology to meet our growing aftermarket operations, and industrialising 3D printing for the industry,” says Brendon McWilliam, executive director, Aftermarket Operations, Asia Pacific. “This ground-breaking innovation is part of the wider technology roadmap by Pratt & Whitney to introduce advanced technologies that integrate AI, robotics and automation across our operations as part of our digital transformation.”
Chin-Huat Sia, principal engineer at Component Aerospace Singapore, adds: “3D printing will be a game-changer for the MRO industry worldwide, especially in servicing even more commercial engines. This technology enables greater flexibility in our inventory management. Following this initiative, both Pratt & Whitney and ST Engineering will examine how additive manufacturing can be applied to other aviation components and other engine types, and further developed to enable hybrid repairs and realise the full potential of 3D printing for commercial aftermarket operations.”
Leveraging its technical expertise, Pratt & Whitney’s engineering team extended ST Engineering’s application of the 3D-printing methods for ground transport systems to produce the aero-engine component for the Pratt & Whitney engine. Both organisations worked closely to ensure that in-house quality and process systems were certified to Pratt & Whitney’s requirements for aftermarket applications.
Due to the novelty of the idea, the technical data underpinning the authorised use of the 3D-printed metallic detail in repair, was completed after several rounds of rigorous reviews and discussions. The subsequent dataset was a result of comprehensive scrutiny of the data by all three parties in the course of exploring the requirements and limitations of existing aviation regulations and 3D printers at ST Engineering.
“To 3D print an aero-engine component for a working air turbine engine is a first for us,” says Tan Chor Kiat, senior vice president - kinetics design & manufacturing, ST Engineering. “This also demonstrates our capability to offer a full turnkey manufacturing solution that not only includes production-level 3D printing, but post processes such as heat treatment and machining.”
Pratt & Whitney’s Component Aerospace Singapore is a repair specialist providing engine part repair for combustion chambers, fuel system components, tubes, ducts and manifolds for the V2500 and PW4000 engines.
