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Additive Manufacturing Background: Additive manufacturing has become one of the most highly touted and talked about fields in recent years. For scientists and engineers at GE Global Research, it has been a more than 20-year research odyssey that today is culminating in exciting developments that are helping to transform our products and our manufacturing operations. For many people, additive manufacturing is synonymous with 3D printing. At GE, additive is 3D printing but also a much broader tool kit of processes such as cold spray, direct write and electron beam technology that represent different ways of “building up” parts. Moreover, additive manufacturing itself is much more than just printing parts. GE uses additive throughout its manufacturing operations, from rapid prototyping and testing new designs to developing new tooling. By 2025, we expect additive manufacturing methods will be used in the design and manufacture of more than 20% of GE’s new product concepts. GE business applications: Next year, GE’s Aviation’s CFM LEAP engine will enter into service with the world’s first 3D printed parts in the functional part of the engine. Each engine will have 19 3D printed fuel nozzles installed that are far more sophisticated in design, yet simpler to produce and more efficient than than conventionally-produced nozzles. With well over 8,000 engines on orders, GE will print more than 100,000 metal parts by 2020. This experience with part development and industry scale-up for Aviation is beginning to translate quickly to other parts of GE’s business portfolio. Much of what GE has acquired in component design, materials and manufacturing process expertise for GE Aviation is being shared with GE’s Power & Water business to jumpstart their additive efforts. GE Power & Water is developing 3D-printed parts for its H-Turbine gas turbine platform to deliver improved efficiency and performance. New 3D designs are enabling part configurations that could not be made conventionally. Through the use of Global Research and the Advanced Manufacturing Works facility located in Greenville, South Carolina, Power & Water is accelerating their efforts towards this technology. In addition to Power & Water, GE’s additive researchers have spread their knowledge and development of new additive tools to GE Oil & Gas and also GE Healthcare. In GE Oil & Gas, for example, 3D printing is being used to develop specialty parts such as control valves used in harsh environments. The GE Store difference: Additive manufacturing started as a research endeavor and has rapidly evolved into a cross-business technology platform where best practices and new developments can be shared from one GE business to another. New material and manufacturing processes that might have otherwise taken years can now be transferred and adapted in a matter of months or even weeks. That’s the power additive manufacturing is bringing to GE’s business portfolio. 7PDF Image | GE Store for Technology
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