By Todd Rockstroh

GE Aviation (GEA) has launched production of their first additively manufactured engine component, the fuel nozzle for the LEAP gas turbine (Fig.1).  This part will see combustion flame and gas temperatures and highly stressed thermal cycles.  There are 19 per engine and the LEAP volume will require over 45,000 fuel circuits to be additively fabricated annually starting in 2018. Our designers exploited additive enabled features to gain: a) 5x life improvement, b) 20 parts consolidated into one, and c) a cost reduction. Continue reading →