Additive fabrication technology and sustainability benefits

We have made great strides in advancing the manufacturing roadmap of next-generation aircraft engines through the deployment of additive fabrication (“AF”) capabilities.

This marks a step-change in how we industrialise complex, safety-critical structures at scale. In 2025, we expanded operations in the production of unique load bearing and non-load bearing structures, beyond our site in Trollhättan, Sweden to additional sites in Newington, USA and Kongsberg, Norway. This geographic expansion strengthens supply resilience and supports global production ramp-up. We reached 100% serial production of the additively manufactured version of the Fan Case Mount Ring (“FCMR”), an essential structural component of the Pratt and Whitney GTF engine on the Airbus A220 and Embraer E195 aircraft.

We are a long-standing strategic partner in the Ariane programme, supplying critical engine components for Ariane 6, including turbines and nozzle extensions for the Vulcain 2.1 and Vinci engines. We continue to advance our additive manufacturing work on the Ariane 6 rocket nozzle, where cost efficiency plays a pivotal role in the engine’s operational economics. This is particularly important with the ramp-up of mission launches from Ariane 6’s successful maiden flight in 2024 to four launches in 2025. AF processes have transformed our operations, reducing welding time by over 200 hours per product and lowering energy use and associated emissions.

Environmental impact

GKN Aerospace’s proprietary AF process utilises materials more efficiently than conventional manufacturing processes. Material efficiency is a critical lever for reducing both cost and environmental impact in aerospace manufacturing. With this production method, we are achieving a buy-to-fly ratio of 7:1 for the FCMR (against a conventional buy-to-fly ratio of 11:1), with further potential optimisation over the coming years and additional benefits from reduced machining and associated energy consumption.

Leveraging the advanced Directed Energy Deposition (“DED”) technique enhances our manufacturing processes while reducing environmental impacts through optimised material utilisation and reduced waste. We have been building minor features with DED for over 10 years, but the FCMR is unique in being the first load carry component with DED to be certified for flight.

Our implementation of AF in the FCMR is demonstrating significant improvements in material utilisation and energy consumption. Based on our assessments, approximately 43 tonnes of titanium were saved in 2025. Potential emissions were reduced by 500 tonnes of CO2e, which is equivalent to removing over 100 passenger vehicles from the road for a year. This represents a meaningful emissions reduction, driven by structural material efficiency, rather than short-term operational optimisation.

Alignment with our environmental strategy

Additive manufacturing has optimised our manufacturing process, minimising material use and waste generation. This aligns with our environmental strategy and contributes to our roadmap for next generation engines development to be lighter, more fuel-efficient, and deliver enhanced functionality.

Lifecycle assessment (“LCA”) methodologies are integral to our decision-making process as we choose optimal applications of additive manufacturing processes. Specific LCAs on critical components, such as the FCMR, indicate that we have achieved approximately a 30% cradle-to-gate emissions reduction, alongside additional environmental benefits. The assessments suggest that further reductions are achievable as additive technology is fully optimised and scaled across platforms.

Social and economic benefits

The expansion of AF is poised to create increased employment opportunities, drive business growth and support the fostering of a culture of innovation. We place a strong emphasis on upskilling and training our workforce, ensuring our people are equipped with the specialist capabilities required to support the long-term adoption of advanced manufacturing technologies.

Ethical considerations

We prioritise ethical sourcing in our supply chain and employ tools like the Assent supplier collaboration and compliance portal for comprehensive risk assessments. The increasing availability of additive manufacturing materials beyond traditional casting houses supports a more competitive, resilient and transparent supply base.