Additive Layer Manufacturing

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The toughest engineering environment

Aerospace engineering demands the highest manufacturing standards are maintained: lives depend on it. We pride ourselves on meeting those standards. As the amount of air travel increases, we're always pushing ourselves to minimise risk and maximise capabilities.

Production Speed
Production Possibilities
Waste Reduction
A part of the Digital Industry

Production Speed

Currently an engine takes 2-3 weeks to build, but the size of our order book means our aim is to increase this to building seven engines per week.
Being able to reduce lead times for engine parts will be key to achieving this. Imagine the benefits of making complex parts in one piece rather than relying on the joining, heat treating, machining and assembly of various individual parts? By removing steps in our processes, we can drastically cut production lead times and improve our products.

Production Possibilities

If our designers can focus on functionality without the traditional limitations of manufacturing – such as halting the design process to begin casting – then a whole new range of possibilities can be opened up.
Additive layer manufacturing (ALM) provides freedom to create solutions as nature does. Just as a human bone is denser and heavier at the joints yet has strength and integrity throughout, Additive layer manufacturing (ALM) allows us to only put materials where they are needed.

Waste Reduction

Getting around the limitations of traditional manufacturing helps us to significantly reduce waste, which is good for both the environment and our bottom line.
Using traditional casting methods, holes are normally drilled, and as a result confined to straight lines. This increases waste (as the drilled material is removed from the final product), and limits the design process as perhaps curved lines would be more efficient.

A part of the Digital Industry

Like any engine, a Gas Turbine has to come back in for servicing and testing. This means service centres have to stock large amounts of spares in order to anticipate repairs on engines.
Depending on the location of a service centre and the time taken to source a specific part, there can be a considerable challenge to delivering on time.
ALM capability at each service centre means that part files will be downloaded and built onsite, in response to demand.

Pioneering 3-D printing

Additive layer manufacturing (ALM) is a fast developing 3-D printing technology and we’re using it to address each of the challenges highlighted here. While it was originally used for developing prototype parts only, we’ve been instrumental in pioneering the use of commercially viable Additive layer manufacturing (ALM) products. Our record-breaking ALM components tested on the Trent XWB-97 engine are only the beginning.

Transforming welding

Additive layer manufacturing (ALM) can be traced back to Stereolithography - which uses a laser beam to cure resin into a desired shape.

Additive layer manufacturing (ALM) Powder Bed Fusion at Rolls-Royce represents two distinct technologies: Laser Powder Bed Deposition where a laser beam melts layers of metal powder to build up a component, and Electron Beam Melting where each layer of powder is melted using a beam of electrons.

To create an Additive layer manufacturing (ALM) part, a 3-D model is sliced into multiple 2-D cross sectional layers. The file is fed into the machine and the laser or electron beam melts each layer, adding the next powder layer on top of the previous one to build upwards.

3-D solutions push boundaries

Working with ALM is challenging and liberating. This insight into our work on the Trent XWB-97 shows our 3-D printed solutions go far beyond traditional manufacturing solutions.

3-D printing’ is the catch-all term for creating 3-D components from 2-D layers. ALM, as Neil Mantle, explains, specifically involves fusing powder “together in layers” and selectively melting only the areas needed.

Melting only the material we want, where we want it, means we maximise material usage and minimise waste. This differs from traditional process such as casting as we don’t need to create solid components and then remove material (e.g. by drilling holes through a component). We create the desired structure from the start.

This means ALM components can be designed exactly as they’d ideally be built and to maximise component function.

Neil’s team put the technology to the test when developing the Trent XWB-97; an engine featuring the largest ever 3-D printed engine components to complete a test flight.

Meet the future of manufacturing

Neil Mantle, our Head of Additive Layering Manufacturing, discusses the impact that ALM will have on future Rolls-Royce technologies – and the role it’s already playing.

Which engine would you like to view?

ALM

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Flexibility

What:

ALM enables changes to be made at almost any point in the design/build process, and saves component manufacturing time and specialist tooling costs.

Benefit:

This added flexibility brings a fluid approach to component design, allowing engineers to explore previously impossible innovative ideas.

Optimisation

What:

ALM enables the creation of complex shapes and forms such as curved internal cooling channels that are not possible in conventional manufacturing.

Benefit:

This means that we can optimise design as nature would – creating the best possible (and lightest weight) components for any given requirement.

Possibilities

Resource use

What:

The precision of ALM means materials are only used where they’re needed – components are lighter in weight but no less strong and effective.

Benefit:

This improve the capability of our products, while reducing material costs and removing the need for costly specialist tooling for each component.

Optimisation

What:

ALM enables the creation of complex shapes and forms such as curved internal cooling channels that are not possible in conventional manufacturing.

Benefit:

This means that we can optimise design as nature would – creating the best possible (and lightest weight) components for any given requirement.

Efficiency

Parts on demand

What:

If a part is required, an engineer can simply upload the spare’s geometry file to an ALM machine and print it off straight away.

Benefit:

This hugely reduces the lead time of delivering spares; what could take weeks, or months, can be done in hours, meaning engines can be back on wing much sooner.

Speed

ALM

View Benefits

Opportunities across our business

As this technology matures, the applications for ALM produced parts are significant. By flying the largest ever aero ALM part on the Trent XWB-97, we have paved the way towards an industrial 3-D printed future. The benefits however are not restricted to the aviation industry; there are possible applications across our entire product portfolio.

Far from being innovation for the sake of innovation, ALM makes our processes simpler, more efficient and will help us provide and mantain even better products. Lots of complex parts that need even more complex processes will be substituted by enhanced ALM parts over time. Because of this we're able to build even more effective components at even greater speed; essential for staying ahead of the increasing demand for aero-engines.

Work continues to ensure before the ALM parts will be introduced into commercial production, but the eventual benefits will ensure we continue to push the boundaries of ALM and 3-D printing.

Opportunities across our business

As this technology matures, the applications for ALM produced parts are significant. By flying the largest ever aero ALM part on the Trent XWB-97, we have paved the way towards an industrial 3-D printed future. The benefits however are not restricted to the aviation industry; there are possible applications across our entire product portfolio.

Far from being innovation for the sake of innovation, ALM makes our processes simpler, more efficient and will help us provide and mantain even better products. Lots of complex parts that need even more complex processes will be substituted by enhanced ALM parts over time. Because of this we're able to build even more effective components at even greater speed; essential for staying ahead of the increasing demand for aero-engines.

Work continues to ensure before the ALM parts will be introduced into commercial production, but the eventual benefits will ensure we continue to push the boundaries of ALM and 3-D printing.

Pioneers in 3-D Printing

Taking 3-D printing to new heights