GKN Aerospace Expands Titanium Additive Manufacturing for Aircraft Engines

GKN Aerospace

Scaling Up Titanium Additive Fabricated Components

UK-based GKN Aerospace is scaling up production of its titanium additive fabricated fan case mount ring (FCMR), aiming for serial production by late 2025. The component is manufactured for Pratt & Whitney’s PW1000G geared turbofan engine, which powers the Airbus A220 and Embraer E195-E2. Rising global demand for narrowbody engines has accelerated the company’s timeline.

GKN currently produces about 30 units per month at its Trollhattan, Sweden facility and expects to reach 40 units monthly by year-end. This ramp-up demonstrates the company’s ability to align with engine manufacturers’ rising production requirements.

Sustainability and Regulatory Approvals Driving Growth

The company’s laser wire deposition additive process reduces material waste by around 40pc per part compared with forging or casting. In 2024, GKN saved 24t of titanium, cutting emissions by 395t of CO₂. These improvements highlight the importance of additive manufacturing in aerospace sustainability.

GKN also received FAA approval for its first additively fabricated structural component and produced its largest all-additive titanium engine case for the CFM RISE engine demonstrator. Regulatory acceptance marks a crucial milestone for the wider adoption of additive technologies in aerospace.

Investment and Future Expansion Plans

In January 2024, GKN invested £50mn ($67mn) to expand additive fabrication capacity. This investment supports its modular production concept, which enables rapid deployment across global sites. Full acceleration of expansion is expected from 2026 onward, reflecting long-term confidence in additive manufacturing.

The Metalnomist Commentary

GKN Aerospace’s titanium additive manufacturing push underscores the industry’s shift toward lighter, sustainable, and cost-efficient production methods. By integrating FAA-certified additive parts into commercial engine programs, GKN positions itself as a key supplier in the evolving aerospace value chain. Long term, additive manufacturing may reshape global titanium demand dynamics as aerospace producers prioritize efficiency and emissions reduction.