GE Additive

Metal additive parts.
For the ready.

CASE STUDY: AK MEDICAL

Leveraging metal additive Electron Beam Melting (EBM) technology, AK Medical was able to scale production of orthopedic implants while developing innovative, customized solutions. For over a decade, the company has successfully used EBM technology to deliver a diverse range of customized, metal additive implants as well as large-scale, off-the-shelf parts.

Results and Benefits

  • Ability to stack parts in the build chamber for increased productivity
  • Integration of mesh structures to enhance osseointegration
  • Customized, patient-specific metal additive implants designed to address complicated diseases
  • 38% cost savings on acetabular cups with EBM technology, compared to other additive technologies
  • 100% increased revenue from metal additive implants during the first half of 2018
  • 8 Arcam EBM Q10plus machines scaled volume production in-house
  • 5 metal additive implants certified by the National Medical Products Administration (NMPA)
     

CASE STUDY: LEAP FUEL NOZZLE

GE Aviation produced its first Federal Aviation Administration-certified additive manufactured fuel nozzle in 2015. Since then, more than 60,000 such fuel tips have been manufactured, reduced inventory for that part by 95% and lowered cost on the component by 30%. 

Results and Benefits

  • 20-to-1 part reduction
  • 25% weight reduction, resulting in reduced fuel consumption over the life of the aircraft
  • 95% inventory reduction
  • 30% cost efficiency improvement
  • 5x more durable
     

CASE STUDY: US AIR FORCE 

The US Air Force is searching for ways to procure crucial spare parts it needs for planes that have been in service for decades and for which used parts are scarce. Using Direct Metal Laser Melting (DMLM) technology, GE’s engineers teamed with USAF to build a 3D-printed sump cover for the GE F110 engine. The sump is part of the oil lubrication system, and the sump cover is a key part of the engine. GE engineers were able to help the US Air Force realize the capability and capacity of metal AM as rapidly as possible to improve readiness and sustainability.

Results and Benefits

  • Increased efficiency while maintaining quality
  • Saved time and costs
  • Enabled on-demand production

CASE STUDY: OPTISYS

Optisys redesigned a large, multi-part antenna assembly into a palm-sized, lighter, one-piece, additive metal antenna. The antenna was printed in aluminum because of its surface conductivity, light weight, corrosion resistance and strength under shock and vibration. Employing additive technology enabled Optisys to break even on machine acquisition just one year after purchasing its first Direct Metal Laser Melting (DMLM) machine.

Results and Benefits

  • 75% reduction in non-recurring costs
  • 95% weight reduction
  • 80% size reduction
  • 100-to-1 part reduction
  • Cycle time reduced from 11 months to 2 months
  • New market expansion: 5 product lines designed for AM

CASE STUDY: PURE COPPER INDUCTOR COIL

A typical inductor coil is comprised of many parts joined together. With EBM, a coil can be made as one durable part for better performance and quality, enabling reduced product costs associated with assembling several parts together. 

Results and Benefits

  • Part durability is increased by combining parts into one build
  • Electrical conductivity > 99% IACS is attained
  • Final parts exhibit highly dense properties

CASE STUDY: GEAR HOB

Using EBM technology, GE manufactured a highly alloyed tool steel gear hob. Additive manufacturing enabled the company to minimize post-processing, save costs and improve wear resistance and ductility.

Results and Benefits

  • Achieved high hardness of 62-63 Rockwell hardness C (HRC)
  • Built free-floating in sintered powder
  • Manufactured in near-net shape