ATP engine NPI triggered the need to accelerate Additive Manufacturing
1.5 year NPI pressure
Aggressive weight targets
Unit cost control
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WEIGHT
CYCLE TIME
$$$
Ultimate game changer for ATP
12 additive parts in ATP engine replacing 855 traditional parts
Improves weight and
performance significantly
Speed … fast prototyping,
reduces lead-times
Simplification … fewer parts,
allows complex shapes
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GE Proprietary InformationSubject to the restrictions on the cover or first page approval.
11/30/2017 6
Torch Igniter case study
• Assy of 6 parts, joined by vacuum brazing
• Dimensions: 59 x 39 x 87 mm
• Operating temperature: max. ~350 °C
• Production rate: 200-300 parts per year
• Production time: 76 days (52 operations)
Air
Fuel Injection
Spark-Plug
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11/30/2017 7
Redesign for Additive
Added Curvature
Blended Corners
Blended Transition
Flange Thickness Reduction
Added Supporting Rib
Current Additive
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11/30/2017 8
And the first trials
Metal powder re-useCurrently 2-3 times; higher cycles driving material cost down
Effective size of the 3DprintersMore volume at the same time, higher asset utilization
Assy Labor costHighly complex assemblies simplified into a single unit
1
2
3
Driving the costs down
Next gen …. combining materials within the unique parts during the print
Design Sophistication
MFG
Co
sts
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Enterprise level disruption … Internet of Things
Design Manufacturing Services
Additive
1Digital Twin
6-8 Engineers
1 Mfg. sources
Inspection Sys.&
Repair Source
11data lake
…powering
300parts
60Engineers 5
Conventional
40data systems
Mfg. sources50+
Turbine frame
Same frame
Repair Sources
Nov 29, 2017 10Confidential. Not to be copied, distributed or reproduced without prior approval.