FAA Certifies GE Aerospace’s 3D Printed Catalyst Turboprop Engine

GE Aerospace Receives FAA Certification for Catalyst Turboprop Engine

GE Aerospace has achieved a major milestone by receiving FAA certification for its Catalyst turboprop engine. The engine is the first to meet the updated standards of the Federal Aviation Administration (FAA) and features advanced 3D-printed components. The certification process involved over 8,000 hours of testing with more than 23 engines and 190 components, marking a significant achievement in aviation technology.

Key Features of the Catalyst Engine

The Catalyst turboprop engine offers impressive features. It provides 18% better fuel consumption and up to 10% higher cruise power compared to its competitors, thanks to its 16:1 overall pressure ratio. The engine is not only more efficient but also incorporates additive manufacturing, producing nearly 30% of its components. This reduces the part count from over 800 to just 12.

Riccardo Procacci, President and CEO of Propulsion and Additive Technologies at GE Aerospace, said, “The certification of the Catalyst engine is a proud moment for our company and a testament to the hard work of our team in designing, developing, and testing this advanced turboprop engine.”

The Additive Manufacturing Revolution

The Catalyst engine showcases the power of additive manufacturing. GE Aerospace has used 3D printing to produce critical components like the turboprop fuel heater, exhaust case, and C Sump. This approach not only simplifies production but also enhances the engine’s performance.

GE Aerospace continues its leadership in additive manufacturing, a legacy established with the LEAP fuel nozzle. The Catalyst engine follows this path, with production taking place across European sites in the Czech Republic, Poland, Germany, and Italy, where each site contributes to component development and manufacturing.

Looking Ahead: Entry into Service

GE Aerospace is committed to supporting the Catalyst engine’s production ramp-up. The engine will soon enter service, providing more efficient turboprop solutions to customers. Paul Corkery, Catalyst General Manager at Avio Aero, said, “We are pleased with the engine’s performance during testing. We will continue supporting Textron Aviation as they prepare the Beechcraft Denali for entry into service.”

As the Catalyst engine approaches its commercial debut, it will revolutionize the aviation industry with its innovative use of 3D printing and superior performance.