Pratt & Whitney Unveils Advanced Additive Repair Solution for GTF Engines

In a significant advancement for the aerospace industry, Pratt & Whitney, a prominent division of RTX, has introduced a groundbreaking additive manufacturing repair solution designed to improve the turnaround time for critical GTF engine components. This innovative approach, developed at the company’s North American Technology Accelerator located in Jupiter, Florida, is poised to revolutionize the way maintenance, repair, and overhaul (MRO) services are delivered in the sector.

The newly developed repair process promises to streamline the GTF engine components' repair time by over 60%. Such a reduction is achieved by employing a method known as Directed Energy Deposition (DED), a 3D printing technology that simplifies and speeds up the repair workflow. By minimizing the number of steps involved in current repair processes, Pratt & Whitney aims to provide its clients with enhanced efficiency, while also significantly cutting down on tooling costs and operational complexities.

Kevin Kirkpatrick, the Vice President of Aftermarket Operations at Pratt & Whitney, stated, "A more agile, additive repair process allows us to better serve our customers by improving turnaround time, while reducing tooling costs, complexity, and set up. At the same time, it reduces our dependency on current material supply constraints." This innovative approach opens the door for wider applications, further bolstering the GTF engine manufacturing process and ensuring a sustainable model for the future.

Over the next five years, Pratt & Whitney anticipates recovering parts valued at approximately $100 million through the active implementation of these additive repairs across its MRO processes. This solution aligns perfectly with the company’s strategic goals of delivering sustainable and efficient engine servicing options.

The collaboration with the Connecticut Center for Advanced Technology and the RTX Research Center played a crucial role in the development of this state-of-the-art technology. The DED method not only accelerates the repair process by reducing heat treatment cycles and machine changeover times, but it also has the potential to restore engine components that wear out during regular operation.

Pratt & Whitney's initiatives are not just limited to GTF engine repairs. In a previous announcement made in April 2024, the company revealed its plans to expand the use of technology accelerators to encompass advanced repairs, digital inspections, adaptive processing, and advanced coatings for various engine parts. This initiative marks a broader effort to employ innovative technologies to enhance overall engine performance and reliability.

Pratt & Whitney also established its Singapore Technology Accelerator in September 2022, which focuses on robotics, advanced inspection, and the connected factory concept. The integration of these accelerators is projected to yield combined annual savings exceeding $24 million, showcasing the company's commitment to maximizing efficiency while minimizing operational costs.

Part of Pratt & Whitney’s GTF MRO network, which includes the industry's leading MRO companies, is supported by 20 facilities across four continents, with additional locations that can provide rapid turnaround services. This global network, branded under Pratt & Whitney's EngineWise® solutions, is designed to deliver exceptional aftermarket services and long-term value to engine operators worldwide.

In essence, Pratt & Whitney is not only advancing its technology through these additive manufacturing processes but is also paving the way for the future of aerospace engineering and maintenance. With the company continuing to innovate, it stands poised to address the critical challenges faced by the aviation sector head-on. For more information about Pratt & Whitney and its products, visit www.prattwhitney.com.

About RTX: RTX is recognized as the world's largest aerospace and defense company, with a workforce of over 185,000 employees globally. The company leverages its industry-leading businesses—Collins Aerospace, Pratt & Whitney, and Raytheon—to push the boundaries of technology and science. With a reported sales figure exceeding $80 billion in 2024, RTX is centered in Arlington, Virginia, and dedicated to redefining connectivity and protection for its clients around the globe.