On February 27, 2025, GE Aerospace‘s Catalyst turboprop engine received certification from the US FAA (the Federal Aviation Administration), marking yet another success for GE Aerospace’s use of additive manufacturing in producing next-generation aircraft engines. After the GE9X, this latest achievement introduces a new era of engine technology and highlights the transformative potential of additive manufacturing in aerospace engineering.
The Catalyst engine makes extensive use of additive manufacturing, mainly through GE Aerospace’s Avio Aero division and facilities but also through external partners. Approximately 30% of its components are 3D printed, which has allowed GE Aerospace to reduce the total number of parts from 855 to just 12. This significant reduction results in a 5% decrease in overall engine weight and a 1% improvement in specific fuel consumption. The use of 3D printing not only optimizes performance but also streamlines production, making the engine more cost-effective and sustainable.
The development of the Catalyst engine has been heavily supported by a collaboration between Avio Aero, GE Additive, and the BEAMIT Group. This partnership focuses on advancing post-processing technologies for additively manufactured components, ensuring they meet the stringent quality and safety requirements of the aerospace industry. By leveraging the latest advancements in additive manufacturing, these companies are pushing the boundaries of what is possible in engine design and production.
The FAA’s Part 33 certification of the Catalyst engine results from an extensive and rigorous testing process. Over 23 test engines underwent more than 8,000 hours of operation, with 190 component evaluations conducted to ensure reliability and compliance. The Catalyst is the first turboprop engine to be certified under the latest FAA standards, which include more than 20 new regulatory requirements. This certification underscores the engine’s cutting-edge design and its ability to meet modern aviation demands.
The Catalyst engine is set to power the Beechcraft Denali, Textron Aviation’s highly anticipated single-engine turboprop aircraft, as well as Airbus’ Eurodrone. Currently undergoing certification, the Denali is designed to compete with aircraft like the Pilatus PC-12, offering enhanced efficiency, performance, and operational flexibility. With the Catalyst engine at its core, the Denali is expected to set new standards in the turboprop market.
The FAA certification of the Catalyst engine represents a pivotal moment in aviation history. By successfully integrating additive manufacturing into mainstream aerospace production, GE Aerospace has enhanced engine performance and paved the way for more sustainable and efficient aircraft in the future, redefining the possibilities in aerospace engineering.
