Material science and process innovation
Materials and process innovation in additive manufacturing
GKN Aerospace advances additive manufacturing through continuous innovation in materials and processes, leveraging deep metallurgical expertise and cutting-edge technologies. By developing and refining solutions for demanding alloys such as titanium and nickel, GKN Aerospace enables the efficient production of complex, high-performance aerospace components.
Recent material science advancements
Recent advancements in additive material science are enabling higher performance, greater reliability, and broader application of additive manufacturing in demanding industries such as aerospace. By improving material properties, process control, and alloy development, these innovations are helping unlock more complex, lightweight, and durable components.
Recent advancements
Development of advanced alloys
Development of advanced alloys
New and optimized alloys (e.g., titanium, nickel superalloys) are being specifically engineered for additive manufacturing, improving strength, fatigue resistance, and high-temperature performance.
Improved powder quality and control
Improved powder quality and control
Enhancements in powder production and characterization (particle size, shape, purity) lead to more consistent builds and better mechanical properties.
In-situ process monitoring
In-situ process monitoring
Real-time monitoring technologies (e.g., melt pool sensors, imaging systems) provide better control over material behavior during printing, reducing defects.
Post-processing innovations
Post-processing innovations
Advanced heat treatments, hot isostatic pressing (HIP), and surface finishing techniques are improving material density, microstructure, and overall performance.
Multi-material and functionally graded materials
Multi-material and functionally graded materials
Innovation at our Global Technology Centres
GKN Aerospace’s Global Technology Centres drive innovation by combining advanced engineering, materials science, and manufacturing expertise to develop next-generation aerospace solutions. While each centre has its own specific area of expertise, they operate as interconnected innovation hubs. Our teams share additive manufacturing (AM) breakthroughs across all our sites to combine AM technology leadership with composites, metallics, and electrical systems. This collaboration allows us to develop complete, end-to-end solutions and speed up the delivery of flight-ready technologies.
01 Trollhättan, Sweden – Engine Systems & Metallics
Trollhättan specialises in engine components and advanced metallics, including high-temperature materials and additive fabrication. It plays a key role in developing durable, high-performance solutions for aero engine applications.
02 Fort Worth, USA – Additive Manufacturing Centre
Fort Worth is dedicated to taking additive manufacturing from early testing to large-scale production. This centre acts as our US innovation hub for scaling and certifying complex metal components. Housing one of the world's largest laser-based AM cells, the hub can additively manufacture large flight ready structures up to 5.6m by 2.5m.
03 Bristol, UK – Advanced Structures & Composites
Bristol focuses on the development of advanced composite structures and lightweight technologies. The team drives innovation in aerostructures, supporting more efficient, sustainable aircraft through cutting-edge design and manufacturing methods.
04 Hoogeveen, Netherlands – Wiring & Electrical Interconnection Systems (EWIS)
Hoogeveen leads innovation in electrical wiring interconnection systems, focusing on lightweight, high-reliability electrical systems that support modern aircraft architectures and increased electrification.
How does GKN Aerospace drive material innovation in additive manufacturing?
GKN Aerospace combines deep metallurgical expertise with advanced research to develop and optimise high-performance alloys, such as titanium and nickel, specifically for additive manufacturing applications.
What role does process innovation play in GKN Aerospace’s manufacturing approach?
Process innovation ensures improved build quality, repeatability, and scalability, enabling the transition from development to high-rate, industrial production.
How are materials and processes developed together at GKN Aerospace?
Material development and process optimisation are closely integrated, ensuring that processing parameters are tailored to achieve the desired mechanical properties and performance.
How does GKN Aerospace ensure consistent quality in new materials and processes?
Through rigorous testing, in-situ monitoring, and qualification procedures, supported by full traceability and adherence to aerospace certification standards.
What benefits do customers gain from GKN Aerospace’s material and process innovation?
Customers benefit from lighter, more efficient components, reduced lead times, improved performance, and access to fully industrialised, certified manufacturing solutions.