End-to-end Additive capability

Fully integrated, end-to-end in-house manufacturing capability

GKN Aerospace delivers a seamless, fully integrated manufacturing solution, from design and additive production to precision machining and finishing, all under one roof. This end-to-end capability simplifies programmes, reduces supplier hand-offs, and improves efficiency, quality, and delivery consistency. As a leading Tier-1 supplier, this consolidated footprint does more than just simplify programmes, it significantly eliminates logistical transport loops, cutting down our supply chain CO2 emissions and embedding sustainability directly into our manufacturing core.

Engineering design

GKN Aerospace engineering design capabilities combine advanced digital tools, materials expertise, and manufacturing know-how to develop optimized, high-performance AM components. By integrating design closely with production processes such as additive manufacturing and precision machining, GKN Aerospace enables innovative, efficient, and production-ready solutions.

Design for advanced manufacturing

GKN Aerospace designs components specifically for additive and hybrid manufacturing, enabling complex geometries, weight reduction, and improved performance.

Integrated engineering approach

Close collaboration between design, materials, and manufacturing teams ensures seamless transition from concept to production, reducing time and risk.

Performance-driven innovation

Engineering solutions are focused on delivering optimized performance, durability, and efficiency for demanding applications, particularly in aerospace and high-value industries.

Additive production

Additive production, also known as additive manufacturing (AM), is a process of building parts layer by layer directly from a digital model. It enables complex geometries, reduced material waste, and part consolidation compared to traditional manufacturing methods.

Laser Powder Bed Fusion (LPBF)

Laser Powder Bed Fusion uses a thin layer of powder (metal or polymer) spread across a build platform. A laser or electron beam selectively melts or sinters the powder to form each layer. • High precision and fine detail • Common for aerospace and medical components • Examples: Selective Laser Melting (SLM), Electron Beam Melting (EBM)

Directed Energy Deposition (DED)

DED-wire: Uses metal wire as the raw material. It offers high deposition rates, clean operations, and is highly cost-effective for large components. DED-powder: Uses fine metal powder blown through a nozzle. It provides excellent detail, smooth surface finishes, and allows for mixing different metals. WAAM (Wire Arc Additive Manufacturing): A specific type of DED-wire that uses an electric welding arc as the heat source. It uses standard welding equipment to build massive metal structures very quickly and at a lower cost.

Reduce waste

LPBF minimizes raw material consumption by precisely melting metal powder into near-net-shape parts, while unused powder can often be recycled for future builds. DED further reduces waste by adding material only to required areas, making it ideal for repairing existing components or producing large structures without extensive machining. Together, these processes improve and reduce the overall environmental impact of manufacturing.

Precision machining

Precision machining is a manufacturing process that produces highly accurate and detailed components by removing material using advanced CNC and tooling technologies. It ensures tight tolerances, superior surface finishes, and reliable performance, making it a key part of modern, high-value production systems.

High accuracy and consistency

Precision machining delivers extremely tight tolerances and repeatable quality, ensuring components meet strict engineering and industry standards.

Critical for high-performance applications

It is essential for industries like aerospace, medical, and automotive, where reliability, safety, and performance are non-negotiable.

Enabler of complex and hybrid manufacturing

Precision machining complements advanced methods like additive manufacturing, enabling finishing, refinement, and integration of complex parts.

Finishing and certification

GKN Aerospace finish and certify capabilities focus on delivering production-ready components through advanced machining, surface finishing, inspection, and certification processes. This ensures every part meets exact specifications, regulatory requirements, and high-performance expectations, particularly in demanding industries like aerospace.

End-to-end quality assurance

GKN Aerospace ensures components meet the highest standards through integrated finishing processes and rigorous inspection and certification procedures.

Compliance with industry standards

Capabilities are aligned with strict aerospace and industrial regulations, ensuring full traceability, documentation, and certification for every part.

Advanced finishing & validation techniques

Includes precision machining, surface treatments, and non-destructive testing (NDT) to guarantee performance, durability, and safety.

It covers the full lifecycle of a component - from engineering design and material selection through additive production, precision machining, finishing, and final certification.

It reduces lead times, minimizes supplier hand-offs, improves communication, and ensures consistent quality across all stages of production.

Design teams work closely with manufacturing experts to optimize components for production methods like additive manufacturing and machining, ensuring efficient and practical designs.

Quality is built into every stage through process control, in-line inspection, and comprehensive testing, supported by full traceability and certification standards.

Yes, the end-to-end capability includes both manufacturing new components and performing additive repair or refurbishment of existing parts.

Through rigorous quality controls, testing, validation, certification processes, and adherence to industry regulations, ensuring every part is certified and flight-ready.