Material Solutions in a Global Perspective
An innovative future for the aviation industry
GKN Aerospace is taking a significant step forward with its new initiative, Material Solutions, focusing on advanced additive manufacturing. This technology, based on powder-based laser welding and wire-fed 3D printing, is essential to the company’s strategy to lead sustainable manufacturing methods and enhance global competitiveness. In this article, Daniel H. Bryn and Henrik Willgohs from GKN Aerospace share insights into how this groundbreaking technology works, as well as the challenges and opportunities in the future production landscape.
Powder Welding: Precision and innovation at its best
One of the most impressive technologies in GKN’s arsenal is powder-based laser welding. The process involves laying down a thin layer of metal powder and welding it together layer by layer with up to 12 lasers, guided by a digital 3D model. Daniel H. Bryn explains that the process takes between 15 and 20 hours, significantly faster than forging or casting components, and offers substantial benefits: “What makes this method so revolutionary is its ability to produce complex components with incredible precision and flexibility,” he says, “components that were previously impossible to manufacture.”
World’s largest AM cell
GKN Aerospace now stands at the forefront of additive manufacturing, boasting one of the world’s largest AM cell and dedicated centers in Trollhättan, Bristol, and Fort Worth. Our state-of-the-art hubs serve as a beacon of progress in additive manufacturing research and development enabling the production of large-scale aerostructures. Through advanced techniques and materials, we unlock unprecedented possibilities in design, production, and performance.
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The process operates at temperatures up to 1,600 degrees Celsius, producing strong, precise parts that withstand demanding environments. This advanced technology highlights the innovation capacity of Material Solutions.
World leaders in wire-based solutions
While powder welding is continuously evolving, GKN Aerospace is already a global leader in wire-fed 3D printing. This technology melts metal wire with a laser, building components layer by layer. In some cases, production can achieve speeds of up to 8 kg per hour, though typical output is slightly lower, around 1–5 kg per hour depending on the product. Material Solutions can produce large components over 3 meters in diameter and weighing several hundred kilograms with the machines they have today, although the technology essentially has no size limitations.
Establishing a presence in the international market
GKN Aerospace has a principle that the further expansion of Material Solutions should be near existing machining facilities to reduce transportation needs, shorten lead times, and maximize sustainability. Once the capacity at current facilities is fully utilized, they plan to build dedicated factories as close to the original locations as possible.
Future investments and ambitions
High Technology and Opportunities in Kongsberg
In Kongsberg, GKN Aerospace is a key player in high-tech manufacturing for the aerospace industry. Today, we focus on precision machining and producing advanced aircraft engine and structure components. This work requires high accuracy and technical expertise, enabling aircraft to fly farther, faster, and more efficiently.
GKN Aerospace Norway (GAN) continuously works towards innovation, sustainability, and ongoing development. We already use additive manufacturing and 3D printing in our production, which has helped us reduce material waste and energy consumption.
If you seek a job in Kongsberg, GAN offers exciting career opportunities in manufacturing engineering, quality control, and technological development. We are always looking for dedicated and skilled workers, engineers, and technicians who want to be part of a global company with strong local roots.
Join GKN Aerospace Norway and help shape the future of aviation technology.
