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[av_heading heading=’Permanova: The road towards a greener future‘ tag=’h1′ style=’blockquote modern-quote modern-centered’ subheading_active=’subheading_below’ show_icon=” icon=’ue800′ font=’entypo-fontello’ size=” av-desktop-font-size-title=” av-medium-font-size-title=” av-small-font-size-title=” av-mini-font-size-title=” subheading_size=’20’ av-desktop-font-size=” av-medium-font-size=” av-small-font-size=” av-mini-font-size=” icon_size=” av-desktop-font-size-1=” av-medium-font-size-1=” av-small-font-size-1=” av-mini-font-size-1=” color=’custom-color-heading’ custom_font=’#0a3054′ subheading_color=” seperator_color=” icon_color=” margin=” margin_sync=’true’ av-desktop-margin=” av-desktop-margin_sync=’true’ av-medium-margin=” av-medium-margin_sync=’true’ av-small-margin=” av-small-margin_sync=’true’ av-mini-margin=” av-mini-margin_sync=’true’ headline_padding=’,,10px,’ av-desktop-headline_padding=” av-desktop-headline_padding_sync=’true’ av-medium-headline_padding=” av-medium-headline_padding_sync=’true’ av-small-headline_padding=” av-small-headline_padding_sync=’true’ av-mini-headline_padding=” av-mini-headline_padding_sync=’true’ padding=’10’ av-desktop-padding=” av-medium-padding=” av-small-padding=” av-mini-padding=” icon_padding=’10’ av-desktop-icon_padding=” av-medium-icon_padding=” av-small-icon_padding=” av-mini-icon_padding=” link=” link_target=” title_attr=” id=” custom_class=” template_class=” av_uid=’av-lq3l3y7f’ sc_version=’1.0′ admin_preview_bg=”]
Henrik Willgohs is now in his second month at Permanova in the role of Director of Business Development & Sales. “It has been an incredibly interesting time with many travels, meetings, discussions, opportunities, and plans on how we can achieve the ambitious sales figures set for us,” he says. In the following, we will try to shed some light on how Additive Manufacturing (AM) could impact the conditions at GAN.
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Permanova is a crucial initiative as part of GKN’s ambition to become climate-neutral by 2050. Once we have started our production and reuse our chips, we could save up to 95% of the CO2 emissions currently generated in the total production of our products (from mining to the finished product). For a single case, this means power savings equivalent to what a household uses in an entire year. We become significantly “greener” with full AM production. Our CEO for GKN Engines, Joakim Andersson, is very enthusiastic about this initiative and speaks warmly about it every time he visits GAN.
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In General
Permanova is the name GKN now uses for its activity in “material solutions.” We are involved in 3D printing or AM of various products that eventually end up in a jet engine. There is an expectation and ambition that we will quickly start selling AM-produced raw materials to GKN Engine’s factories. We will also produce products for markets outside Aerospace. It is something entirely new and exciting for us. Currently, the plan is to achieve a turnover of $100 million within 3 years and $500 million within 8 years. These are significant figures and involve a rapid establishment of Permanova factories around. One of them is planned for Kongsberg, and the plan is to use existing floor space initially, primarily in building 83. This means that Permanova Norway and GAN will be located side by side. It also opens up the possibility for Permanova to use shared resources that GAN has, which are not fully utilized, such as heat treatment, NDT, FPI, and X-ray. We will buy hours used there from GAN. In practice, we only need to buy and install AM machines to start producing 3D-printed aircraft engine parts in Kongsberg.
Read about our contribution to Kongsberg Agenda!
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[av_heading heading=’What is Permanova?’ tag=’h2′ style=’blockquote modern-quote’ subheading_active=” show_icon=” icon=’ue800′ font=’entypo-fontello’ size=” av-desktop-font-size-title=” av-medium-font-size-title=” av-small-font-size-title=” av-mini-font-size-title=” subheading_size=” av-desktop-font-size=” av-medium-font-size=” av-small-font-size=” av-mini-font-size=” icon_size=” av-desktop-font-size-1=” av-medium-font-size-1=” av-small-font-size-1=” av-mini-font-size-1=” color=’custom-color-heading’ custom_font=’#ffffff’ subheading_color=” seperator_color=” icon_color=” margin=” margin_sync=’true’ av-desktop-margin=” av-desktop-margin_sync=’true’ av-medium-margin=” av-medium-margin_sync=’true’ av-small-margin=” av-small-margin_sync=’true’ av-mini-margin=” av-mini-margin_sync=’true’ headline_padding=” headline_padding_sync=’true’ av-desktop-headline_padding=” av-desktop-headline_padding_sync=’true’ av-medium-headline_padding=” av-medium-headline_padding_sync=’true’ av-small-headline_padding=” av-small-headline_padding_sync=’true’ av-mini-headline_padding=” av-mini-headline_padding_sync=’true’ padding=’10’ av-desktop-padding=” av-medium-padding=” av-small-padding=” av-mini-padding=” icon_padding=’10’ av-desktop-icon_padding=” av-medium-icon_padding=” av-small-icon_padding=” av-mini-icon_padding=” link=” link_target=” title_attr=” id=” custom_class=” template_class=” av_uid=’av-lq3le91h’ sc_version=’1.0′ admin_preview_bg=”][/av_heading]
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Permanova is GKN’s initiative in “material solutions” with a focus on Additive Manufacturing (AM). The goal is to become climate-neutral by 2050, reduce CO2 emissions through AM production, and collaborate closely with GAN (GKN Aerospace Norway) in Kongsberg.
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[av_heading heading=’What is Permanova?’ tag=’h2′ style=’blockquote modern-quote’ subheading_active=” show_icon=” icon=’ue800′ font=’entypo-fontello’ size=” av-desktop-font-size-title=” av-medium-font-size-title=” av-small-font-size-title=” av-mini-font-size-title=” subheading_size=” av-desktop-font-size=” av-medium-font-size=” av-small-font-size=” av-mini-font-size=” icon_size=” av-desktop-font-size-1=” av-medium-font-size-1=” av-small-font-size-1=” av-mini-font-size-1=” color=’custom-color-heading’ custom_font=’#ffffff’ subheading_color=” seperator_color=” icon_color=” margin=” margin_sync=’true’ av-desktop-margin=” av-desktop-margin_sync=’true’ av-medium-margin=” av-medium-margin_sync=’true’ av-small-margin=” av-small-margin_sync=’true’ av-mini-margin=” av-mini-margin_sync=’true’ headline_padding=” headline_padding_sync=’true’ av-desktop-headline_padding=” av-desktop-headline_padding_sync=’true’ av-medium-headline_padding=” av-medium-headline_padding_sync=’true’ av-small-headline_padding=” av-small-headline_padding_sync=’true’ av-mini-headline_padding=” av-mini-headline_padding_sync=’true’ padding=’10’ av-desktop-padding=” av-medium-padding=” av-small-padding=” av-mini-padding=” icon_padding=’10’ av-desktop-icon_padding=” av-medium-icon_padding=” av-small-icon_padding=” av-mini-icon_padding=” link=” link_target=” title_attr=” id=” custom_class=” template_class=” av_uid=’av-lq3lejvm’ sc_version=’1.0′ admin_preview_bg=”][/av_heading]
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Permanova is GKN’s initiative in “material solutions” with a focus on Additive Manufacturing (AM). The goal is to become climate-neutral by 2050, reduce CO2 emissions through AM production, and collaborate closely with GAN (GKN Aerospace Norway) in Kongsberg.
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[/av_cell_one_half][/av_layout_row][av_one_full first min_height=” vertical_alignment=’av-align-top’ space=” row_boxshadow_width=’10’ row_boxshadow_color=” margin=’0px’ margin_sync=’true’ av-desktop-margin=” av-desktop-margin_sync=’true’ av-medium-margin=” av-medium-margin_sync=’true’ av-small-margin=” av-small-margin_sync=’true’ av-mini-margin=” av-mini-margin_sync=’true’ mobile_breaking=” mobile_column_order=” border=” border_style=’solid’ border_color=” radius=” radius_sync=’true’ min_col_height=” padding=” padding_sync=’true’ av-desktop-padding=’,50px,,50px’ av-medium-padding=” av-medium-padding_sync=’true’ av-small-padding=” av-small-padding_sync=’true’ av-mini-padding=” av-mini-padding_sync=’true’ svg_div_top=” svg_div_top_color=’#333333′ svg_div_top_width=’100′ svg_div_top_height=’50’ svg_div_top_max_height=’none’ svg_div_top_opacity=” svg_div_bottom=” svg_div_bottom_color=’#333333′ svg_div_bottom_width=’100′ svg_div_bottom_height=’50’ svg_div_bottom_max_height=’none’ svg_div_bottom_opacity=” column_boxshadow_width=’10’ column_boxshadow_color=” background=’bg_color’ background_color=” background_gradient_direction=’vertical’ background_gradient_color1=’#000000′ background_gradient_color2=’#ffffff’ background_gradient_color3=” src=” attachment=” attachment_size=” background_position=’top left’ background_repeat=’no-repeat’ highlight_size=’1.1′ animation=” animation_duration=” animation_custom_bg_color=” animation_z_index_curtain=’100′ parallax_parallax=” parallax_parallax_speed=” av-desktop-parallax_parallax=” av-desktop-parallax_parallax_speed=” av-medium-parallax_parallax=” av-medium-parallax_parallax_speed=” av-small-parallax_parallax=” av-small-parallax_parallax_speed=” av-mini-parallax_parallax=” av-mini-parallax_parallax_speed=” css_position=” css_position_location=’,,,’ css_position_z_index=” av-desktop-css_position=” av-desktop-css_position_location=’,,,’ av-desktop-css_position_z_index=” av-medium-css_position=” av-medium-css_position_location=’,,,’ av-medium-css_position_z_index=” av-small-css_position=” av-small-css_position_location=’,,,’ av-small-css_position_z_index=” av-mini-css_position=” av-mini-css_position_location=’,,,’ av-mini-css_position_z_index=” link=” linktarget=” link_hover=” title_attr=” alt_attr=” mobile_display=” mobile_col_pos=’0′ id=” custom_class=” template_class=” aria_label=” av_uid=” sc_version=’1.0′]
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Organization
The Permanova name emerged through the acquisition of Permanova Laser Systems (PLS) based in Gothenburg. They manufacture machines for AM production with wire welding. Everything they produce in terms of machines in the coming years will be used internally. This means that we won’t be selling any machines externally in the near future. We also engage in AM production using powder, and these machines are sourced from other machine suppliers. Permanova is essentially a startup. We have significant plans and high ambitions to quickly transition out of the startup phase, but we are clearly in the startup phase for now. Below is the current organization of Permanova, which will evolve as we establish our own factories worldwide (possibly 3-5 factories). Currently, we have around 60 employees, with PLS constituting approximately half.
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[av_image src=’https://gknposten.no/wp-content/uploads/2023/12/GKN-Organisjasjonskart-Permanova-storre.png’ attachment=’6356′ attachment_size=’full’ copyright=” caption=” image_size=” styling=” box_shadow=’none’ box_shadow_width=’10’ box_shadow_color=” align=’center’ font_size=” overlay_opacity=’0.4′ overlay_color=’#000000′ overlay_text_color=’#ffffff’ animation=’no-animation’ animation_duration=” animation_custom_bg_color=” animation_z_index_curtain=’100′ parallax_parallax=” parallax_parallax_speed=” av-desktop-parallax_parallax=” av-desktop-parallax_parallax_speed=” av-medium-parallax_parallax=” av-medium-parallax_parallax_speed=” av-small-parallax_parallax=” av-small-parallax_parallax_speed=” av-mini-parallax_parallax=” av-mini-parallax_parallax_speed=” hover=” appearance=” css_position=” css_position_location=’,,,’ css_position_z_index=” av-desktop-css_position=” av-desktop-css_position_location=’,,,’ av-desktop-css_position_z_index=” av-medium-css_position=” av-medium-css_position_location=’,,,’ av-medium-css_position_z_index=” av-small-css_position=” av-small-css_position_location=’,,,’ av-small-css_position_z_index=” av-mini-css_position=” av-mini-css_position_location=’,,,’ av-mini-css_position_z_index=” transform_perspective=” transform_rotation=’,,,’ transform_scale=’,,’ transform_skew=’,’ transform_translate=’,,’ av-desktop-transform_perspective=” av-desktop-transform_rotation=’,,,’ av-desktop-transform_scale=’,,’ av-desktop-transform_skew=’,’ av-desktop-transform_translate=’,,’ av-medium-transform_perspective=” av-medium-transform_rotation=’,,,’ av-medium-transform_scale=’,,’ av-medium-transform_skew=’,’ av-medium-transform_translate=’,,’ av-small-transform_perspective=” av-small-transform_rotation=’,,,’ av-small-transform_scale=’,,’ av-small-transform_skew=’,’ av-small-transform_translate=’,,’ av-mini-transform_perspective=” av-mini-transform_rotation=’,,,’ av-mini-transform_scale=’,,’ av-mini-transform_skew=’,’ av-mini-transform_translate=’,,’ mask_overlay=” mask_overlay_shape=’blob’ mask_overlay_size=’contain’ mask_overlay_scale=’100%’ mask_overlay_position=’center center’ mask_overlay_repeat=’no-repeat’ mask_overlay_rotate=” mask_overlay_rad_shape=’circle’ mask_overlay_rad_position=’center center’ mask_overlay_opacity1=’0′ mask_overlay_opacity2=’1′ mask_overlay_opacity3=” link=” target=” title_attr=” alt_attr=” img_scrset=” lazy_loading=’disabled’ id=” custom_class=” template_class=” av_element_hidden_in_editor=’0′ av_uid=” sc_version=’1.0′ admin_preview_bg=”][/av_image]
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Competence in Kongsberg
The establishment of a factory in Kongsberg will be very exciting but also challenging. Space needs to be cleared, equipment must be brought in, NPIs must be implemented at GAN (implementation of new products), and we must initiate recruitment and knowledge transfer. This last aspect is a crucial prerequisite for success. Currently, GKN has a significant amount of expertise in Sweden and not as much in Norway. Recruitment will happen through regular advertisements, and there is hope for a large number of interested candidates. These individuals will be employed by GAN but will be part of the Permanova organization and report in that direction.
There is an extreme focus and investment in AM within our market segment. What we specifically aim to do in Kongsberg is unique. The main difference from others is that we build parts in Kongsberg using wire welding (most others use powder), and the parts are larger than what others deliver. Currently, small parts are mostly produced elsewhere (for example, at Norsk Titan). This will be a unique competence, and our AM activity will represent a significant technological leap for the Norwegian industry. I believe there is reason to expect significant political interest in GKN in Kongsberg as a result. It is also assumed that the environmental aspect will attract attention. The savings are quite substantial. It could be an “eye-opener” for many.
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[av_heading heading=’What is Additive Manufacturing?’ tag=’h2′ style=’blockquote modern-quote’ subheading_active=” show_icon=” icon=’ue800′ font=’entypo-fontello’ size=” av-desktop-font-size-title=” av-medium-font-size-title=” av-small-font-size-title=” av-mini-font-size-title=” subheading_size=” av-desktop-font-size=” av-medium-font-size=” av-small-font-size=” av-mini-font-size=” icon_size=” av-desktop-font-size-1=” av-medium-font-size-1=” av-small-font-size-1=” av-mini-font-size-1=” color=’custom-color-heading’ custom_font=’#ffffff’ subheading_color=” seperator_color=” icon_color=” margin=” margin_sync=’true’ av-desktop-margin=” av-desktop-margin_sync=’true’ av-medium-margin=” av-medium-margin_sync=’true’ av-small-margin=” av-small-margin_sync=’true’ av-mini-margin=” av-mini-margin_sync=’true’ headline_padding=” headline_padding_sync=’true’ av-desktop-headline_padding=” av-desktop-headline_padding_sync=’true’ av-medium-headline_padding=” av-medium-headline_padding_sync=’true’ av-small-headline_padding=” av-small-headline_padding_sync=’true’ av-mini-headline_padding=” av-mini-headline_padding_sync=’true’ padding=’10’ av-desktop-padding=” av-medium-padding=” av-small-padding=” av-mini-padding=” icon_padding=’10’ av-desktop-icon_padding=” av-medium-icon_padding=” av-small-icon_padding=” av-mini-icon_padding=” link=” link_target=” title_attr=” id=” custom_class=” template_class=” av_uid=’av-lq3leuv7′ sc_version=’1.0′ admin_preview_bg=”][/av_heading]
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Additive Manufacturing (AM), or additive production, is an advanced manufacturing method where 3D objects are built layer by layer by adding material. This contrasts with traditional subtractive methods such as cutting or casting. AM enables complex geometries and reduces waste, and is used in industries such as aerospace and medicine.
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[av_heading heading=’What is Additive Manufacturing?’ tag=’h2′ style=’blockquote modern-quote’ subheading_active=” show_icon=” icon=’ue800′ font=’entypo-fontello’ size=” av-desktop-font-size-title=” av-medium-font-size-title=” av-small-font-size-title=” av-mini-font-size-title=” subheading_size=” av-desktop-font-size=” av-medium-font-size=” av-small-font-size=” av-mini-font-size=” icon_size=” av-desktop-font-size-1=” av-medium-font-size-1=” av-small-font-size-1=” av-mini-font-size-1=” color=’custom-color-heading’ custom_font=’#ffffff’ subheading_color=” seperator_color=” icon_color=” margin=” margin_sync=’true’ av-desktop-margin=” av-desktop-margin_sync=’true’ av-medium-margin=” av-medium-margin_sync=’true’ av-small-margin=” av-small-margin_sync=’true’ av-mini-margin=” av-mini-margin_sync=’true’ headline_padding=” headline_padding_sync=’true’ av-desktop-headline_padding=” av-desktop-headline_padding_sync=’true’ av-medium-headline_padding=” av-medium-headline_padding_sync=’true’ av-small-headline_padding=” av-small-headline_padding_sync=’true’ av-mini-headline_padding=” av-mini-headline_padding_sync=’true’ padding=’10’ av-desktop-padding=” av-medium-padding=” av-small-padding=” av-mini-padding=” icon_padding=’10’ av-desktop-icon_padding=” av-medium-icon_padding=” av-small-icon_padding=” av-mini-icon_padding=” link=” link_target=” title_attr=” id=” custom_class=” template_class=” av_uid=’av-lq3lg03w’ sc_version=’1.0′ admin_preview_bg=”][/av_heading]
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Additive Manufacturing (AM), or additive production, is an advanced manufacturing method where 3D objects are built layer by layer by adding material. This contrasts with traditional subtractive methods such as cutting or casting. AM enables complex geometries and reduces waste, and is used in industries such as aerospace and medicine.
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GAN Impact on AM
Area
A considerable area is needed to accommodate the entire future need for Permanova. Initially, we will take space that GAN has vacated as a result of the TEC/TRF transfer to GAS. There are local expansion potentials that must be utilized in the long run. In the image below, I have highlighted green areas and red circles where AM production will take place in the first phase. Heat-treat and NDT are resources we will share with GAN. XR means X-ray.
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Activity and Products
The very first thing that needs to happen now is to make space for Permanova Norway in building 83. After that, we will conduct a LEAN event to see how we can best utilize the available space and facilitate the best possible flow. At the same time, we must start recruiting. We will need a local manager and many engineers and operators. Welding expertise is an advantage, but there are also several other roles to be filled. The next step will likely be to bring in machines for placement and commissioning. After that, we will start our own internal training and begin testing gradually. We have ambitions to complete all of this before we see 2025 on the calendar. 2025 will be used to adapt operations and materials, and no later than 2026, we will deliver the first blanks to GAN for machining.
There is still an ongoing discussion about products and where they should be produced, so I cannot say much about that. What is certain is that, in the coming years, we will focus on AM production cases, and for GAN, these will be cases relevant to our Center of Excellence (CoE). Shafts are, of course, desired as well, but it becomes highly complex, and the requirements cannot currently be met with such a presentation. Shaft production through AM is therefore a bit further in the future. I also think a considerable amount of time is needed for customer maturation regarding AM-produced shafts.
The consequence of establishing a Permanova factory in Kongsberg can, however, be confidently said to lead to an extreme increase in the number of cases produced per year at GAN. To be conservative, it will likely be over 3000 machining cases at GAN per year in the 2020s, but it could be significantly more in the longer term if all goes well. The prospects are therefore very bright.
Personnel
Some information has already been provided about personnel. For Permanova, a key will be to build competence. Another crucial factor is a high pace in the buildup. We naturally hope that GAN personnel will be interested in this, but we believe that we also need to recruit externally. In any case, those we potentially get from GAN will need to be replaced, so there must be a parallel process of recruiting within GAN. Additionally, the increased volume of cases will create a need for more people. Therefore, much of 2024 will be a “recruitment year,” which is pleasant in itself and also a good signal of our growth ahead.
Overall, we will likely have doubled the number of GKN employees in Kongsberg in the not-too-distant future.
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Timing
The implementation of Permanova Norway must happen quickly if we are to meet our goals. The current ambition is to deliver the first AM-based parts to customers by no later than 2026. This means we have a lot to do in a short time. Therefore, we aim to have established the beginning of what we will build on as Permanova Norway by the end of 2024. We also hope to have initiated testing of various products by then. This may sound optimistic, but we have our top boss Joakim with us, so there is a good basis for success.
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Permanova is truly an interesting place to be at the moment. We are the unit in GKN responsible for the initiative in “material solutions” and perhaps the most crucial factor in achieving our ambitious environmental goals for 2050. GKN Engines has an ambitious goal to more than double its turnover from now until 2030, up to $3 billion. Permanova will account for 1/6 of that turnover, and a pivotal point for this endeavor will be in Kongsberg and in very close cooperation with GAN.
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