The world before and after… 3D print. The GE story. Milan Slapak GE Aviation Nov 29, 2017 Prague
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The world before and after…
3D print. The GE story.
Milan SlapakGE AviationNov 29, 2017Prague
Welcome to the new revolution…
© General Electric Company – All rights reserved
ATP engine NPI triggered the need to accelerate Additive Manufacturing
1.5 year NPI pressure
Aggressive weight targets
Unit cost control
Confidential. Not to be copied, distributed or reproduced without prior approval. Nov 29, 2017 3
WEIGHT
CYCLE TIME
$$$
Ultimate game changer for ATP
12 additive parts in ATP engine replacing 855 traditional parts
Improves weight and
performance significantly
Speed … fast prototyping,
reduces lead-times
Simplification … fewer parts,
allows complex shapes
Confidential. Not to be copied, distributed or reproduced without prior approval. Nov 29, 2017 4
Optimizing existing product
GE Proprietary InformationSubject to the restrictions on the cover or first page approval.
11/30/2017 6
Torch Igniter case study
• Assy of 6 parts, joined by vacuum brazing
• Dimensions: 59 x 39 x 87 mm
• Operating temperature: max. ~350 °C
• Production rate: 200-300 parts per year
• Production time: 76 days (52 operations)
Air
Fuel Injection
Spark-Plug
GE Proprietary InformationSubject to the restrictions on the cover or first page approval.
11/30/2017 7
Redesign for Additive
Added Curvature
Blended Corners
Blended Transition
Flange Thickness Reduction
Added Supporting Rib
Current Additive
GE Proprietary InformationSubject to the restrictions on the cover or first page approval.
11/30/2017 8
And the first trials
Metal powder re-useCurrently 2-3 times; higher cycles driving material cost down
Effective size of the 3DprintersMore volume at the same time, higher asset utilization
Assy Labor costHighly complex assemblies simplified into a single unit
1
2
3
Driving the costs down
Next gen …. combining materials within the unique parts during the print
Design Sophistication
MFG
Co
sts
Confidential. Not to be copied, distributed or reproduced without prior approval. Nov 29, 2017 9
Enterprise level disruption … Internet of Things
Design Manufacturing Services
Additive
1Digital Twin
6-8 Engineers
1 Mfg. sources
Inspection Sys.&
Repair Source
11data lake
…powering
300parts
60Engineers 5
Conventional
40data systems
Mfg. sources50+
Turbine frame
Same frame
Repair Sources
Nov 29, 2017 10Confidential. Not to be copied, distributed or reproduced without prior approval.
Business & General Aviation
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