RTX's Pratt & Whitney launches additive GTF repair solution to improve turnaround time

Rhea-AI Summary

RTX's Pratt & Whitney has unveiled a groundbreaking additive manufacturing repair solution for GTF engine components, developed at their North American Technology Accelerator in Jupiter, Florida. The new technology will reduce process time by over 60% using Directed Energy Deposition, a 3D printing method.

The innovation is expected to recover $100 million worth of parts over the next five years through implementation across the global GTF MRO network. The solution eliminates several steps in the current repair method, particularly benefiting machine changeover and heat treat cycles reduction.

The project, developed in collaboration with the Connecticut Center for Advanced Technology and RTX Research Center, will be scaled throughout their 20-shop MRO network across four continents. Combined with other accelerator programs, Pratt & Whitney expects annual savings of at least $24 million.

Positive

• New repair technology reduces process time by over 60%
• Expected recovery of $100 million worth of parts over 5 years
• Projected annual savings of $24 million from accelerator programs
• Reduces dependency on material supply constraints
• Reduces tooling costs and complexity

Negative

• None.

New technology developed at company's North American Technology Accelerator in Jupiter, Florida

EAST HARTFORD, Conn., April 8, 2025 /PRNewswire/ -- Pratt & Whitney, an RTX (NYSE: RTX) business, has developed a new additive manufacturing repair for critical GTF engine components that will reduce process time by more than 60 percent. The company is currently working to industrialize the repair, which will then be scaled and applied throughout the global GTF MRO network. Pratt & Whitney expects to recover $100 million worth of parts over the next five years through the implementation of additive repairs throughout its MRO process.

"A more agile, additive repair process allows us to better serve our customers by improving turnaround time, while reducing tooling costs, complexity and set up," said Kevin Kirkpatrick, vice president of Aftermarket Operations at Pratt & Whitney. "At the same time, it reduces our dependency on current material supply constraints. Additive technology has the potential to support a range of critical GTF part repairs and we're actively working to explore additional opportunities for implementation."

Developed by Pratt & Whitney's North American Technology Accelerator in Jupiter, Florida, the new solution will enable repair to GTF structural case features using a 3D printing method known as Directed Energy Deposition. By eliminating several steps in the current repair method, this new technology reduces overall process time by more than 60 percent, with the greatest benefits via minimization of machine changeover and reduced heat treat cycles.  Pratt & Whitney collaborated with the Connecticut Center for Advanced Technology and the RTX Research Center to develop the new technology. Future applications will also be used to restore components worn through normal engine operation.  

In April 2024, Pratt & Whitney announced the intent to expand its use of technology accelerators to include advanced repairs, digital inspection, adaptive processing, and coating and masking for compressor and fan parts, blades, cases, and more. Pratt & Whitney's North American Technology Accelerator serves as a complement to its Singapore Technology Accelerator, established in September 2022 with a focus on robotics, advanced inspection, connected factory and digital twin. Combined annual savings of at least $24 million are expected from Pratt & Whitney's accelerator programs.

The Pratt & Whitney GTF MRO network is comprised of the industry's leading MRO companies and includes 20 shops across four continents and additional sites with quick turn capability. The GTF MRO network is part of Pratt & Whitney's EngineWise® solutions, which provide engine operators with a variety of aftermarket services resulting in long-term, sustainable value.

About Pratt & Whitney
Pratt & Whitney is a world leader in the design, manufacture and service of aircraft engines and auxiliary power units. To learn more visit www.prattwhitney.com.

About RTX
RTX is the world's largest aerospace and defense company. With more than 185,000 global employees, we push the limits of technology and science to redefine how we connect and protect our world. Through industry-leading businesses – Collins Aerospace, Pratt & Whitney, and Raytheon – we are advancing aviation, engineering integrated defense systems for operational success, and developing next-generation technology solutions and manufacturing to help global customers address their most critical challenges. The company, with 2024 sales of more than $80 billion, is headquartered in Arlington, Virginia.

For questions or to schedule an interview, please contact corporatepr@rtx.com.

 

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SOURCE RTX

FAQ

How much will RTX save with the new GTF repair technology over the next 5 years?

RTX expects to recover $100 million worth of parts over the next five years through the implementation of additive repairs in their MRO process.

What is the process time reduction achieved by RTX's new additive manufacturing repair?

The new additive manufacturing repair solution reduces process time by more than 60% for GTF engine components.

How many MRO shops are in RTX's Pratt & Whitney GTF network?

The GTF MRO network includes 20 shops across four continents, plus additional sites with quick turn capability.

What are the expected annual savings from RTX's Pratt & Whitney accelerator programs?

Combined annual savings of at least $24 million are expected from Pratt & Whitney's accelerator programs.

What type of 3D printing technology does RTX use for the new GTF repair solution?

RTX uses Directed Energy Deposition, a 3D printing method, for the new GTF repair solution.