Honeywell Aerospace, Phoenix, announces that its additively manufactured #4/5 bearing housing for the ATF3-6 Dassault aircraft engine has received certification from the U. S. Federal Aviation Administration. This is the first certified, flight-critical engine part built via additive manufacturing. The part is currently in production and has been installed on an in-service engine. It is a major structural component in the ATF3-6 turbofan engine used on the Dassault Falcon 20G maritime patrol aircraft, which are used by the French Navy for patrol and search-and-rescue missions.
Designed by Garrett in the 1960s and certified in 1967, only about a dozen ATF3-6 engines are still flying. This presents sourcing and supply chain challenges for operators of Dassault Falcon 20G aircraft. Additionally, the #4/5 bearing housing is complicated to manufacture — making it extremely costly for operators to replace due to the low quantity of orders placed. This challenge is combined with the high cost of tools needed to produce parts by traditional casting methods. However, the parts can be 3D-printed much more quickly and in smaller quantities without the need for expensive tools.
“Though not many are in service, Honeywell is responsible for supporting and maintaining these engines,” says Jon Hobgood, vice president of manufacturing engineering, Honeywell Aerospace. “We had to find a way to address these supply-chain issues and keep these aircraft flying. We were able to use our expertise in additive manufacturing to produce the qualified part much faster, reducing our lead time from approximately two years to two weeks.”
