GKN Aerospace boosts additive manufacturing with US expansion

GKN Aerospace has announced the expansion of its Newington, Connecticut facility with a new production line dedicated to additive manufacturing of the fan case mount ring (FCMR), a vital component of the Pratt & Whitney GTF engine that powers the Airbus A220 and Embraer E195-E2. The expansion will create new jobs and further strengthen GKN Aerospace’s presence in the United States.

The FCMR programme has become the largest flight-critical additive component to receive FAA certification and is on course for full serial production by the end of 2025. Its core structure, the additively manufactured ‘hot size ring’, is already being produced at GKN Aerospace’s Trollhättan facility in Sweden, with final machining carried out in Newington. The expansion will enable production ramp-up and help meet broader market demand.

GKN Aerospace’s proprietary additive manufacturing process reduces material use, shortens production lead times, and is expected to deliver more than 70% material savings. Importantly, it will also strengthen global supply chains by providing an alternative production method.

Joakim Andersson, President Engines, GKN Aerospace, commented: “This expansion in Connecticut marks a major milestone for GKN Aerospace and our Fan Case Mount Ring programme. The combination of strong local support, the highly skilled workforce and the availability of an aerospace network and infrastructure here allows us to bring our latest additive fabrication technology into industrial-scale production, creating jobs and supporting our long-term relationship with Pratt & Whitney. We are proving that additive fabrication is not only technically transformative but also delivers real-world benefits in sustainability, lead-time and predictability for our customers.”

Sébastien Aknouche, SVP Material Solutions, GKN Aerospace stated: “Today we already produce around 30 FCMR units per month at our Trollhättan facility. Expanding our cutting-edge technology, developed in Sweden, to the US will support the full volume of FCMR production in one place. As well as ramping up our production for the FCMR, it will also enable us to expand our additive fabrication offering to other customers in the USA.”

GKN Aerospace operates two facilities in Connecticut, at Newington and Cromwell, employing more than 450 people across the state. The latest investment underscores the company’s ongoing commitment to innovation and customer delivery, and follows its US$50 million investment in 2024 to expand sustainable additive manufacturing capabilities for civil and military engine platforms worldwide.