SerpApi.Org
RTX’s Pratt & Whitney has joined forces with GKN Aerospace to develop a large additively manufactured structural component for the F135 fighter engine, marking a new push to introduce industrial-scale 3D printing into military propulsion. The companies plan to certify the component by the end of 2028 after producing a full-scale demonstrator a year earlier.
The effort centers on the F135 turbofan that powers the F-35 Lightning II. Engineers will examine whether additive manufacturing can produce a structural engine case that matches the performance and compatibility of conventionally manufactured hardware. Norway’s Defence Materiel Agency (NDMA) is supporting the development program.
Large engine structures
GKN Aerospace will lead the engineering work from its facility in Kongsberg, Norway. The company plans to manufacture the demonstrator using its laser-directed energy deposition with wire (L-DEDw) process, which deposits molten metal layer by layer to create large components.
Unlike smaller aerospace parts already produced through additive manufacturing, structural engine cases present a different challenge. They must withstand extreme temperatures, high mechanical loads, and tight dimensional tolerances without affecting engine performance. The partners intend to produce a full-scale engine case that remains fully interchangeable with parts already used across the F135 fleet.
Engineers will not redesign the engine for the project. Instead, they aim to prove that additive manufacturing can deliver an equivalent component capable of meeting the program’s certification requirements. A demonstrator is scheduled for completion in 2027 before the project moves into qualification and certification activities through 2028.
Production beyond prototypes
For aerospace manufacturers, additive manufacturing has increasingly moved beyond producing brackets and low-volume components. Companies are now evaluating whether the technology can handle larger structural hardware that traditionally requires extensive forging, machining, and finishing operations.
That shift could eventually shorten production schedules and reduce dependence on long supply chains for complex metal parts. Using wire feedstock also limits material waste compared with subtractive machining, where manufacturers remove significant amounts of metal to reach the final shape.
Whether those advantages translate into military propulsion remains an open question. The Pratt & Whitney and GKN Aerospace program will generate data on manufacturing quality, repeatability and certification requirements before the technology moves closer to operational use.
Supporting future readiness
The companies say the collaboration supports the long-term sustainment of the F135 program while expanding manufacturing options for future aerospace platforms. “I am pleased to see this collaboration bringing together strong industrial capabilities and advanced manufacturing expertise,” said Sébastien Aknouche, senior vice president at GKN Aerospace.
He said the initiative reflects the company’s ambition to industrialize additive manufacturing for demanding aerospace applications. Pratt & Whitney also framed the project as part of its broader technology roadmap for the F135 engine.
“This agreement reflects our continued focus on advancing technologies that support the long-term needs of the F135 program,” said Chris Johnson, vice president of the F135 Program at Pratt & Whitney. Johnson added that the company values its collaboration with GKN Aerospace as both sides evaluate manufacturing methods that could strengthen future engine readiness. If the effort reaches its planned milestones, it will provide one of the clearest demonstrations yet that additive manufacturing can produce large structural components for front-line military aircraft without compromising certification standards.
