GKN Aerospace accelerates additive fabrication industrialisation
for Fan Case Mount Ring
Excellent progress on Fan Case Mount Ring (FCMR) transition from initial production phase to 100% serial production by end of 2025.
FCMR is a critical component at heart of Pratt & Whitney GTF engine powering Airbus’ A220 and Embraer E195-E2.
Major industrial and certification milestones achieved, including FAA approval and largest ever additive component delivered.
GKN Aerospace has taken a major step forward in the industrialisation of additive fabrication (AF), with the Fan Case Mount Ring (FCMR) programme now progressing toward full rate production by the end of 2025. The company is already delivering at volume from its Trollhättan facility, in Sweden, with output set to ramp up from around 30 units per month today to 40 per month by year end.
Earlier this year, GKN Aerospace marked its 200th delivery of an additively fabricated ‘hot size ring’, the core structure of the FCMR, to its Newington facility, in the USA, for final machining. The company is on track to deliver run rate volumes to support the increasing market demand of the GTF engine for the Airbus 220 and Embraer 195-E2.
With the additively manufactured FCMR now in serial production, and key additive insertion activities for GE Aerospace now also underway, current results demonstrate around 40% material waste reduction per part compared to traditional manufacturing methods. In the future, GKN Aerospace expects to achieve more than 70% material savings, while reducing end-to-end lead times from nine months to as little as four weeks.
In the past 12 months, GKN Aerospace has achieved several key additive certification and technology milestones. These include FAA approval for its first additively fabricated critical structural component and successful delivery of its largest ever all-additive component: a large-scale, titanium engine case for the CFMI RISE technology demonstrator. Produced using fully automated direct energy deposition, the structure met casting-quality standards and demonstrated the full design and build potential of large-scale additive fabrication.
GKN Aerospace is a global multi-technology leader in the aerospace industry, specialising in the development and delivery of cutting-edge aerostructures and engine systems. Our unrivalled products, systems, and services are integral to 90% of today’s aircraft ranging from helicopters, business jets, passenger planes and advanced air mobility vehicles to state-of-the-art fighter aircraft.
Our commitment to innovation and cutting-edge technology is evident in the application of lightweight composites, additive fabrication, electrical wiring interconnection systems, and ground breaking engine systems, reducing both weight and cost in today’s aircraft and engines. GKN Aerospace is at the forefront of sustainable technology, developing breakthrough solutions to achieve emission-free flight. Our global technology centres collaborate with industry partners around the world to accelerate the development of pioneering technologies, including hydrogen-powered propulsion and all-electric flight.
GKN Aerospace is a global multi-technology leader in the aerospace industry, specialising in the development and delivery of cutting-edge aerostructures and engine systems. Our unrivalled products, systems, and services are integral to 90% of today’s aircraft ranging from helicopters, business jets, passenger planes and advanced air mobility vehicles to state-of-the-art fighter aircraft.
Our commitment to innovation and cutting-edge technology is evident in the application of lightweight composites, additive fabrication, electrical wiring interconnection systems, and ground breaking engine systems, reducing both weight and cost in today’s aircraft and engines. GKN Aerospace is at the forefront of sustainable technology, developing breakthrough solutions to achieve emission-free flight. Our global technology centres collaborate with industry partners around the world to accelerate the development of pioneering technologies, including hydrogen-powered propulsion and all-electric flight.
Operating in 12 countries, GKN Aerospace employs a workforce of 16,000 employees across more than 30 locations. GKN Aerospace has global sales of £3.4bn and is listed under its parent company name Melrose Industries PLC (LSE:MRO).
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.