Material Solutions in a Global Perspective
Where Are We Headed?
Material Solutions (MS) represents a major strategic shift for GKN Aerospace Engines and plays a pivotal part in our future growth strategy. MS is our response to global disruptions such as COVID-19 and geopolitical tensions, as taking greater responsibility for our supply chain has become increasingly important. MS also supports GKN’s long-term goal of reducing carbon emissions to net zero by 2050.
At GKN, Material Solutions refers specifically to Additive Fabrication (AF) – which uses Additive Manufacturing (3D printing) in combination with traditional processes. GKN/MS provides additive solutions to replace traditional forgings and castings with more sustainable and flexible alternatives. At the same time, we offer more sustainable substrate options to the industry, supplying both GKN sites and external customers. Our unique global AF capability combined with our own Product Solutions/Operational Excellence and Aftermarket/MRO gives GKN a strong competitive edge in aerospace manufacturing.
Global Perspective and Regionalisation
With Material Solutions, we have the advantage of localising close to any production site. We can produce our raw material/substrates next door rather than relying on a limited number of casting and forging houses. Instead of waiting for suppliers to ramp up, GKN takes control of critical parts of the supply chain – proactively identifying weak points and stepping in where it makes strategic sense.
In short, we do not eliminate external suppliers but instead use Additive Fabrication to produce parts internally or work with a broader range of smaller, more localised suppliers. As a result, we enhance the regional value chain while offering our customers shorter lead times, improved logistics control, greater supply security, and stronger resilience in the face of disruptions like tariffs or border issues.
Powder-based welding
Preparedness and Supply Security
With Additive Fabrication, Material Solutions can reduce reliance on the few established aerospace suppliers facing capacity constraints, thereby broadening and reinforcing the supply chain. Unlike traditional casting methods that now face lead times of up to 2-3 years, additive processes can have a product ready in just a few weeks. Ultimately, this approach reduces global dependency and enhances supply security for government-driven programs where local suppliers are preferred.
Additive technology is the ideal solution regarding national preparedness. It provides flexibility and speed, ensuring that critical manufacturing capabilities are available within key regions when needed.
Sustainability and Circular Economy
Sustainability has become an increasingly important aspect of our additive development, and Additive Fabrication is essential to achieving our long-term sustainability target – net zero CO₂ emissions by 2050.
This goal requires new production methods and engineering solutions for cleaner engine emissions. By using AF, we cut the manufacturing CO₂ emissions by up to 90%. We estimate that additively manufactured GKN products alone could reduce global aviation emissions by 7 million tons annually. They also use 2 to 8 times less raw material than traditional methods, significantly lowering waste and resource use.
An example of GKN’s sustainability in action today is the Fan Case Mount Ring for the PW GTF-engine PW1500 used on the Airbus A220. We currently produce each part using 160 kg less titanium, about 40% less material than traditional methods, and the manufacturing process cuts emissions by around 40% compared to conventional production. The goal for this part is a 96% reduction in CO₂ emissions and more than 200 kg less titanium usage.
A circular economy is crucial for achieving long-term sustainability. While GKN is still in the early stages of implementing circular practices, we will meet our goals by reusing powder, carvings, and discarded or scrapped products to produce new powder or wire as needed. We anticipate closer collaboration with leading powder or wire suppliers as part of our circular economy strategy.
Competitiveness and Economy
Higher costs typically arise in the early stages of any technological shift, and Additive Fabrication is no exception. However, Material Solutions has already proven that AF can be both sustainable and economically competitive. Additive production uses significantly less material, has shorter lead times, fewer hours in the machine and higher flexibility. Raw material use is also reduced to mainly argon gas and selected metal wires and powders. In addition to being cost-competitive, AF delivers a positive cash impact through lowered inventory.
While our products are already highly competitive, additive production will, over time, outperform traditional methods and deliver considerable sustainability gains. So, while the upfront investment in AF technology may be high, the long-term economic benefits are significant, especially as the technology scales. To support this growth and stay competitive, GKN sees the need for closer collaboration with raw material suppliers, especially for wire, powder, and argon gas – this also aligns with our circular economy strategy. Moving forward, it is evident that ensuring cost control and securing the supply of key resources will be essential.
Future and Innovation
Material Solutions is at the start of an ambitious journey, aiming to grow rapidly in an industry still adapting to the full potential of additive technologies. While the jet engines market may not match our pace, Material Solutions is pushing progress daily, confident that Additive Fabrication will become a key enabler of future manufacturing. In fact, in 5-10 years, we expect Material Solutions to be three times the size of GKN Norway today.
It is also worth noting that we are not the only players within the additive area, but GKN holds distinct advantages. These include combined additive and final machining capabilities, full in-house ownership of all essential processes, fabrication capacity to weld additively developed parts into larger products, and partnership agreements with all the major jet engine customers.
These strengths make GKN a one-stop supplier in one of the world’s most demanding and complex technology sectors, a position that opens doors to a whole range of other markets – primarily non-aerospace defence. Ultimately, while jet engines remain the focus, our technologies are well-suited to other high-tech markets.
Material Solutions: A long-term solution
Material Solutions is part of GKN’s global strategy to tackle the industry’s most pressing challenges: material scarcity, environmental impact, and production inefficiency. We see Additive Fabrication as a long-term solution and the go-to technology for companies aiming to cut lead times, reduce costs, and enable innovative design. GKN is at the forefront of this shift, constantly developing technologies that meet rising mineral demands while delivering sustainable, accessible products.
As Additive Fabrication moves from niche to mainstream, we are scaling innovation, strengthening supplier partnerships, and embedding sustainability into core processes. For us, AF is more than a competitive advantage – it is a necessary evolution in manufacturing. As our Director Henrik Willgohs puts it:
The future will be based on additive fabrication for positive cost, cash, material utilisation, flexibility and sustainability reasons – take advantage of this future-based manufacturing technology now.»
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.