GKN Aerospace expands AM fabrication in the US at Newington (CT) facility

GKN Aerospace has expanded its Newington, Connecticut facility with the launch of a new production line dedicated to the additive fabrication of the Fan Case Mount Ring (FCMR). This critical component, part of Pratt & Whitney’s GTF engine programme powering the Airbus A220 and Embraer E195-E2, marks a significant step forward in industrializing advanced manufacturing technologies within the United States.

The new line represents a major milestone in GKN Aerospace’s journey to bring additive fabrication into full-scale production. The FCMR programme is already recognized as the largest flight-critical additive component to secure FAA certification and is on track to achieve 100 percent serial production by the end of 2025. Currently, the additively fabricated “hot size ring” core structure is produced at GKN Aerospace’s Trollhättan facility in Sweden before being machined in Newington. With the expansion, the company will consolidate and accelerate production to meet growing demand, strengthening both U.S. and global supply chains.

The proprietary WAAM-based additive fabrication process developed by GKN Aerospace delivers significant sustainability and efficiency benefits. By reducing material consumption and shortening production lead times, the process is projected to save more than 70 percent of materials compared to traditional methods. It also provides an alternative production pathway that increases resilience across aerospace supply chains.

Joakim Andersson, President of Engines at GKN Aerospace, emphasized the importance of the investment:
“This expansion in Connecticut marks a major milestone for GKN Aerospace and our Fan Case Mount Ring programme. The combination of strong local support, a highly skilled workforce, and the availability of an established aerospace network allows us to bring our latest additive fabrication technology into industrial-scale production. It creates jobs, supports our long-term relationship with Pratt & Whitney, and proves 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, Senior Vice President of Material Solutions at GKN Aerospace, noted the strategic significance of the move: “Today we already produce around 30 FCMR units per month at our Trollhättan facility. Expanding this cutting-edge technology to the U.S. will enable us to scale production to full volumes in one location. In addition to ramping up FCMR production, this facility expansion also opens the door for us to extend our additive fabrication capabilities to other U.S. customers.”

The investment builds upon GKN Aerospace’s £50 million commitment in 2024 to expand its sustainable additive manufacturing capabilities across civil and military engine platforms. With two facilities in Connecticut—Newington and Cromwell—and more than 450 employees in the state, the company is reinforcing its long-term presence in the region. The expansion has been made possible through collaboration with the Connecticut Department of Economic and Community Development and the Governor’s Office, who provided support in bringing this initiative to life.