Rolls-Royce opens AM development cell at Bristol facility
Technology will be used to develop critical parts for next-gen stealth fighter jets
Best known for its luxury cars, British company Rolls-Royce also specializes in the production of engines and propulsion systems for aerospace and defense. As part of this line of work, the company has just opened a new Additive Manufacturing Development Cell at its Defence Assembly and Operations facility in Bristol. The development cell, which houses metal LPBF technology, will focus on the production of critical parts for next-gen aircraft engines.
The AM cell, which is supported with funding from the UK Ministry of Defence, is based in a custom-built 350-square-meter space with controlled temperature and air pressure. This environment has been tailored to achieve optimal results for printed metal parts.
The company plans to use its new AM capability to advance the Global Combat Air Programme (GCAP), a joint initiative between the UK, Italy, and Japan to develop sixth-generation stealth fighter jets. Specifically, AM will be used to develop and manufacture critical aircraft engine parts optimized for weight and fuel efficiency.
“Across Rolls-Royce we are committed to the continued development and enhancement of our technologies to meet the demands of today, while providing scalable infrastructure required for the future,” said Andy Higginson, Senior VP of Manufacturing, Assembly and Test at Rolls-Royce. “Programmes like FCAS [Future Combat Air System] and GCAP will be fundamental to the UK’s future aerospace sector and capabilities like additive manufacturing will be crucial to enabling innovation at pace, driving cost savings and enhancing the skills and capabilities of our people.”
In addition to developing aircraft engine parts with reduced weight, Rolls-Royce expects its AM cell will enable it to speed up development cycles and part delivery timeframes, as well as achieve greater cost efficiencies. Another key benefit of integrating AM for production is that it can allow the company to reduce waste, in terms of material usage, and energy in terms of the amount of power used to develop components.
At the AM cell’s recent opening, Luke Pollard MP, the Minister for Defence Readiness and Industry was present along with Claire Hazelgrove, MP for Filton and Bradley Stoke, where Rolls-Royce’s Defence Assembly and Operations facility is based. For them, the new AM cell is also relevant in terms of its job creation and upskilling.
“This new facility in Bristol is a clear sign of UK industry investing in the skills and technology we need to stay ahead,” commented Pollard. “By using the latest manufacturing techniques to build lighter, more efficient components, Rolls-Royce is helping to keep British engineers at the forefront of innovation—all the while creating and sustaining skilled jobs right here in Bristol.”
The AM development cell in Bristol grows Rolls-Royce’s adoption of metal AM for critical part development. In recent years, the company installed a number of metal AM systems (specifically the SLM500) for the production of aircraft engine components for the Pearl10X. The UK manufacturer is also part of the Tornado 2 Tempest project, which turns old Tornado aircraft into titanium material for 3D printing.
