GKN Aerospace to lead additive mfg. research program

Farnborough, U.K – GKN Aerospace, a global first tier supplier of airframe structures, engine components, transparencies, and fuel/flotation systems, is to lead a consortium of UK companies in a 3.5-year, GBP13.4 million research and development program called Horizon (AM) that builds on GKN’s extensive and fast-developing additive manufacturing capability. 

 

The Horizon (AM) team includes GKN Aerospace, Renishaw, Delcam, and the Universities of Sheffield and Warwick. The program is backed by the UK’s Aerospace Technology Institute (ATI).

 

Horizon (AM) will take a number of promising additive manufacturing (AM) techniques from research and development through to viable production processes, able to create components that could be as much as 50% lighter than their conventional counterparts, with complex geometries that cannot be cost effectively manufactured today. These new processes will unlock innovations in low-drag, high-performance wing designs and lighter, even more efficient engine systems – and lead to dramatic reductions in aircraft fuel consumption and emissions.

 

The program will focus initially on using AM techniques to create near net shape parts which require very little machining. This will dramatically improve the ‘buy to fly’ ratio of the part by reducing the considerable cost in time and material wastage associated with the conventional machining of metal forgings. With material wastage as high as 90% for some parts, a significant reduction here will also provide major environmental benefits.

 

Rich Oldfield, technical director, GKN Aerospace explains: “AM incorporates a range of hugely promising manufacturing technologies that the UK aerospace sector must fully understand and exploit if it is to retain its position as the largest national aerospace industry outside the USA. This strong consortium has the expertise and understanding to continue the process of industrializing these technologies for use in both current program updates and next-generation aircraft.”

 

The ATI is an independent institute established as collaboration between government and industry to lead and challenge the UK’s Aerospace technology strategy, and through GBP 2 billion of secured R&T investment, maintain and grow the UK’s competitive position in world-leading capabilities, preserving high-value design and manufacturing jobs in the UK.

 

Within the ATI, industry experts and academics drive the UK’s intellectual leadership in whole aircraft, aerodynamics, propulsion, aerostructures, and advanced systems. The ATI will strive to sustain and grow an internationally competitive Aerospace sector through investment in technologies consistent with commercial aircraft updates, new aircraft, the sector’s strengths and the added economic value to the UK.