3D printing in the creation of the Boeing 777

Source: 3dprintingmedia.network

3D printing was used to create the Boeing 777X, in which both GE9X engines have more than three hundred 3D-printed parts, of which about 80% are titanium-aluminum engine blades. These parts were manufactured by teams from General Electric (GE) at the aerospace company Avio Aero in Cameri, Italy, and the GE Additive Technology Center (ATC) in West Chester, Ohio.


Each engine has about 300 3D printed parts. Photo: frequentflyers.ru

The first flight of an aircraft with 3D-printed parts was broadcast live on a special website. The joint development of Boeing and GE confirms the effectiveness and feasibility of using additive manufacturing technologies in the aerospace industry.


Additive manufacturing in action: Boeing 777X makes its first flight with 3D-printed GE9X engines

David Joyce, President and CEO of GE Aviation:

“Today’s flight is a testament to both companies' outstanding work and dedication. We are proud of our brainchild and are making every conceivable and unimaginable effort to provide this aircraft with the latest GE technology. "

The latest technology refers to the most advanced materials, such as ceramic matrix composites, and production methods, including 3D printing, which together make the GE9X the most economical engine in its class that GE has ever produced.

Each GE9X engine consists of more than 300 parts, including a fuel nozzle tip that accurately atomizes the fuel-air mixture into the combustion chamber, low-pressure turbine blades, and a heat exchanger.

Another printed element, an inductor, helps remove dust, sand and other debris that enters the engine, which significantly extends its life. Parts of this type are so complex to manufacture that they have never before been used inside a GE commercial jet engine.

Zach Studt, Senior Process Engineer, GE Aviation:

“An inductor cannot be made in any other way than using 3D printing. Thus, additive manufacturing improves engine performance. As often happens, the introduction of a more advanced production process helps to get a better product. In the future, most engines are likely to come with one version or another of this 3D printed inductor. ”

Designed on the basis of the most commercially successful Boeing 777 aircraft, which was first commissioned in 1994, with the introduction of advanced technologies used in Boeing 787 Dreamliner airbuses, the 777X will be the largest and most economical twin-engine jet in the world.

Thanks to revolutionary advances in aerodynamics and engine building, the 777X airbus will provide a 10% reduction in fuel consumption and emissions, as well as 10% reduction in operating costs compared to competitors.

The creators of the GE9X engine promise industry-leading performance and seamless integration with the 777 and 787 Dreamliner product lines. But high performance is only part of the story.


Photo: frequentflyers.ru The

manufacturer expects the Boeing 777X, with its spacious wide cabin, new custom architecture and innovations borrowed from the 787 Dreamliner, to become the most preferred civilian aircraft in the short and medium term.

This is largely made possible thanks to the GE9X engine. It is the world's largest and most powerful engine for commercial aircraft, using GE's cutting-edge technology over the past decade, making the GE9X the most economical engine in its class.

Antroine Townes, ATC Site Leader:

“In the past, designers were trapped in the production methods they had, now we can remove these limitations and design the best engine solution, not the best production solution.”