GKN’s US$8.4m Additive Manufacturing Programme with AFRL

GKN Aerospace has announced an US$8.4m partnership with the US Air Force Research Laboratory (AFRL). 

The collaboration is set to focus on laser metal deposition with wire (LMD-W) technology, a type of additive manufacturing, commonly referred to as 3D printing. 

The AFRL is the primary scientific and research division of the US Air Force. It operates across nine technology areas and has 40 other operations across the globe.

What is LMD-W tech?

LMD-W technology uses a laser beam to melt metal wire onto substrate through a coaxial nozzle. It is a type of additive manufacturing that enables the production of complex titanium parts used in both the aerospace and automotive industry. 

The best-known forms of additive manufacturing are selective laser sintering, stereolithography, fused deposition modelling, direct metal laser sintering and laser metal deposition.

Additive manufacturing offers enormous benefits, including less hard tooling and assembly. In the long run, additive manufacturing can completely change the way products are designed and built, as well as distributed, sold and serviced, according to McKinsey. 

TITAN-AM’s technology

The partnership between AFRL And GKN is called Titanium Industrialisation and Technology Advancement for Near-net Additive Manufacturing (TITAN-AM). 

The programme will be executed from GKN Aerospace’s Global Technology Centre in Fort Worth, Texas, where GKN collaborates with US defence and aerospace partners. 

The partnership is focused on advancing and industrialising LMD-W technology for next-generation aerostructures. The technology will address key areas needed for structural aerospace applications. 

David Bond, CTO Airframes for GKN Aerospace, says: “TITAN-AM represents a significant step forward in additive manufacturing for aerospace structures. 

“By combining our deep manufacturing expertise with AFRL’s vision, we aim to accelerate the readiness of LMD-W technology and demonstrate its value on operational titanium structural components.”

The partnership's focus

GKN and AFRL will work on the industrialisation of LMD-W processes for large-scale titanium aerostructure components, as well as the development of robust titanium material datasets to ensure structural performance and reliability.

The partners will work on advancing simulation capabilities to optimise structural design and manufacturing outcomes in structural aerospace. They will also develop non-destructive inspection (NDI) techniques tailored for additive manufacturing processes

GKN and AFRL will seek to demonstrate the technology on selected aerospace structural components.

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About GKN Aerospace

GKN Aerospace operates across 13 countries at 41 manufacturing locations, employing approximately 15,000 people. It is a market leader in aerostructures, engine systems, transparencies and wiring systems.

GKN Aerospace in serial production of major additively manufactured structures that are in the air today, including the fan case mount ring for the Pratt & Whitney GTF (Geared Turbofan) engine family. 

These components are produced using additive manufacturing in Sweden and the US, and are in service on aircraft such as the Airbus A220 and Embraer E195-E2.