3D printing makes Rolls-Royce’s Advance3 lighter and more efficient

Rolls-Royce’s Advance3 demonstrator engine has now completed over 100 test hours and is showing excellent results from parts made through 3D printing, or additive layer manufacturing (ALM), and from ceramic matrix composites (CMC).

The advantages of ALM include quicker design and manufacturing: complex engine parts with multiple pieces can be manufactured in fewer parts or even as a single complete part, improving lead times and allowing components to be redesigned quickly and easily during the development phase. ALM also increases production efficiency and reduces component weight. Meanwhile CMCs are lighter than metal alternatives and can withstand higher temperatures for longer, contributing to improved efficiency.

To date, engineers have downloaded millions of data points from the tests, which began last November and saw the engine achieve full power in July 2018.

The Advance3 demonstrator is testing a new engine core that will deliver optimum fuel efficiency and low emissions. It is a key element in Rolls-Royce’s future technology strategy to develop the Advance core for the UltraFan® engine design that will be available from 2025 and will offer a 25% improvement in fuel efficiency compared with a first generation Trent engine. The Advance3 demonstrator programme is co-funded through the Aerospace Technology Institute (ATI) in association with Innovate UK and Clean Sky 2.

See Rolls-Royce press release here https://www.rolls-royce.com/media/press-releases/2018/11-10-2018-3-d-printed-parts-and-new-materials-help-rolls-royce-to-engine-test-success.aspx