MRO & Manufacturing
GKN Aerospace and USAF Launch $8.4M Additive Manufacturing Program
GKN Aerospace and the US Air Force Research Lab launch TITAN-AM to advance 3D printing of large titanium aerospace structures using LMD-w technology.

This article is based on an official press release from GKN Aerospace.
On April 13, 2026, GKN Aerospace and the U.S. Air Force Research Laboratory (AFRL) announced the launch of a collaborative $8.4 million manufacturing initiative. The program, officially named TITAN-AM (Titanium Industrialization and Technology Advancement for Near-net Additive Manufacturing), is designed to industrialize and advance 3D printing technologies for large-scale aerospace structures.
According to the official press release, the partnership will focus heavily on Laser Metal Deposition with Wire (LMD-w) technology. By shifting away from traditional subtractive manufacturing methods, the initiative aims to make the production of next-generation titanium aerostructures faster, more sustainable, and highly efficient.
The TITAN-AM program will be executed at GKN Aerospace’s Global Technology Centre located in Fort Worth, Texas. We understand from the announcement that the project is expected to yield significant advancements for both commercial aviation and domestic defense supply chains by proving the viability of additively manufactured titanium components in operational environments.
The TITAN-AM Program and LMD-w Technology
The core of the $8.4 million TITAN-AM investment centers on maturing Laser Metal Deposition with Wire (LMD-w). As detailed in the program’s background materials, LMD-w is a directed energy deposition (DED) process that utilizes a high-powered laser to melt a continuously fed titanium wire, building complex structures layer by layer.
Titanium is a highly sought-after material in the aerospace sector due to its exceptional strength-to-weight ratio and resistance to corrosion. However, traditional manufacturing requires machining parts from massive titanium blocks. According to industry data cited in the announcement, conventional subtractive manufacturing can result in a “Buy-to-Fly” ratio of up to 95 percent, meaning that up to 95 percent of the raw titanium is machined away as scrap waste. LMD-w technology drastically reduces this material waste while simultaneously shortening production lead times.
The TITAN-AM program aims to accelerate the readiness of LMD-w technology and demonstrate its value on operational titanium structural components for both defense and commercial aerospace platforms, according to the GKN Aerospace announcement.
Five Critical Focus Areas
To successfully qualify LMD-w for rigorous aerospace structural applications, the press release outlines five specific focus areas for the TITAN-AM program:
- Industrialization: Scaling the LMD-w processes to accommodate large-scale titanium aerostructure components.
- Material Datasets: Developing comprehensive and robust titanium material datasets to guarantee structural performance, safety, and long-term reliability.
- Advanced Simulation: Improving digital simulation capabilities to optimize structural designs and accurately predict manufacturing outcomes before physical printing begins.
- Inspection Techniques: Pioneering Non-Destructive Inspection (NDI) methods specifically tailored for the unique properties of additive manufacturing processes.
- Practical Demonstration: Validating the technology by physically manufacturing and rigorously testing selected aerospace structural components.
Leveraging Fort Worth’s “Cell 3” Infrastructure
The execution of the TITAN-AM program relies heavily on existing infrastructure at GKN Aerospace’s Fort Worth facility. The company will leverage its massive “Cell 3” additive manufacturing system, which was officially commissioned in June 2023.
According to the provided background data, Cell 3 is recognized as the world’s largest known laser-directed energy deposition additive manufacturing cell. The system is equipped with a 20-kilowatt laser, features up to 10 axes of motion, and operates within a massive inert environment. This setup is capable of printing titanium components up to 5 meters (over 16 feet) in length, making it uniquely suited for the large-scale goals of the AFRL partnership.
Partner Backgrounds and Expertise
Both partners bring decades of specialized experience to the TITAN-AM initiative. GKN Aerospace noted in its release that it possesses over 20 years of experience in additive technologies. The company is already utilizing 3D printing in serial production for commercial-aircraft; for instance, GKN produces the additively manufactured fan case mount ring for the Pratt & Whitney GTF (Geared Turbofan) engine family, which currently operates on the Airbus A220 and Embraer E195-E2.
The U.S. Air Force Research Laboratory (AFRL) has been researching fusion-based additive manufacturing for aerospace alloys since the late 1990s. The military’s ongoing investment in this sector is driven by strategic imperatives: maintaining and modernizing legacy weapon systems, reducing reliance on foreign-sourced raw materials, and fortifying the domestic defense industrial base.
AirPro News analysis
At AirPro News, we view the TITAN-AM initiative as a critical step in bridging the aerospace industry’s “Valley of Death”, the notoriously difficult regulatory and financial transition from successful prototype to certified, flight-ready hardware. By explicitly focusing on the creation of robust material datasets and specialized non-destructive inspection (NDI) techniques, GKN and the AFRL are directly addressing the primary hurdles to Federal Aviation Administration (FAA) and Department of Defense (DoD) certification.
Furthermore, the broader supply chain implications cannot be overstated. The U.S. defense sector has faced persistent bottlenecks in traditional heavy forging and casting. By transitioning to near-net additive manufacturing, the industry can onshore critical manufacturing capabilities, allowing the U.S. to build large-scale aircraft components locally and on-demand. Coupled with the massive reduction in raw titanium waste, this shift represents a significant leap forward for both supply chain resilience and aerospace sustainability.
Frequently Asked Questions (FAQ)
What is the TITAN-AM program?
TITAN-AM (Titanium Industrialization and Technology Advancement for Near-net Additive Manufacturing) is an $8.4 million collaborative program between GKN Aerospace and the U.S. Air Force Research Laboratory (AFRL) to advance 3D printing for large titanium aircraft structures.
What is LMD-w technology?
Laser Metal Deposition with Wire (LMD-w) is a 3D printing process that uses a high-powered laser to melt a continuously fed metal wire, building up a component layer by layer. It significantly reduces material waste compared to traditional machining.
Where will the manufacturing take place?
The program will be executed at GKN Aerospace’s Global Technology Centre in Fort Worth, Texas, utilizing their massive “Cell 3” additive manufacturing system.
Sources: GKN Aerospace
Photo Credit: GKN Aerospace
MRO & Manufacturing
Pratt & Whitney Canada Signs MRO Deal with AirBorneo Airways
Pratt & Whitney Canada secures a four-year PW127M maintenance agreement with AirBorneo Airways, supported from Singapore through 2030.

Pratt & Whitney Canada has secured a four-year maintenance, repair, and overhaul agreement with AirBorneo Airways to support the PW127M engines powering the carrier’s legacy ATR 72-500 regional turboprop fleet. Announced on September 24, 2026, the contract ensures operational continuity for the airline’s critical Rural Air Services network across East Malaysia through 2030.
In a press release issued by RTX Corporation, Pratt & Whitney Canada confirmed the engine work will be conducted primarily at its newly expanded facility in Singapore. The localized support is designed to reduce turnaround times and maintain high dispatch reliability for AirBorneo, which relies heavily on its turboprop fleet to connect remote and underserved communities.
Bridging the fleet transition
AirBorneo Airways officially commenced operations under its own identity on January 1, 2026, following the Sarawak government’s acquisition of MASwings from Malaysia Aviation Group. The transition included taking over the Rural Air Services network and an existing fleet of eight ATR 72-500 aircraft.
While the airline placed a firm order for eight new ATR 600-series aircraft at the Singapore Airshow on February 3, 2026, those airframes are scheduled for delivery between 2027 and 2029. The new maintenance agreement with Pratt & Whitney Canada bridges this gap, ensuring the older PW127M-powered aircraft remain viable and reliable until the fleet modernization is complete.
AirBorneo Chief Executive Officer Megat Ardian Aminuddin emphasized the importance of regional support for the carrier’s specific operational profile.
“Having this support based in Singapore puts our engine maintenance and repairs close to home and our aircraft back in service faster. That confidence gives us the operational certainty we need to consistently serve our customers on our intra-Borneo routes where reliable air transport is a vital link for remote communities.”
Expanded maintenance capabilities in the Asia-Pacific
The agreement highlights Pratt & Whitney Canada’s recent investments in its Asia-Pacific infrastructure. By expanding its Singapore facility to accommodate broader turboprop maintenance capabilities, the manufacturer can serve regional operators without the logistical delays of shipping engines to North America or Europe.
Anthony Rossi, Vice President of Customer Service for Pratt & Whitney Canada, stated the company worked closely with the airline to develop a solution that manages costs while supporting high dispatch availability. Rossi noted the contract reinforces the manufacturer’s commitment to advancing its maintenance services to meet evolving customer requirements.
The PW100 engine family, which includes the PW127M, has accumulated more than 200 million flight hours over 40 years of regional turboprop operations. When AirBorneo begins receiving its new ATR 72-600 and ATR 42-600 aircraft, those airframes will be powered by the newer PW127XT Series engines, continuing the operator’s relationship with the RTX business unit.
AirPro News analysis
We view this four-year agreement as a pragmatic stopgap for AirBorneo Airways as it navigates the complex transition from a legacy MASwings operation to an independent, modernized state-owned carrier. The Rural Air Services network operates in challenging environments where aircraft downtime directly impacts community lifelines. By utilizing Pratt & Whitney Canada’s expanded Singapore facility, AirBorneo mitigates supply chain risks and turnaround delays associated with aging airframes. For RTX, which reported $88 billion in sales in 2025 and employs over 180,000 people globally, securing the legacy maintenance contract ensures continuous revenue from the PW127M while seamlessly transitioning the customer to the PW127XT platform later in the decade.
Sources: RTX
Photo Credit: Pratt & Whitney Canada
MRO & Manufacturing
Chromalloy Earns FAA PMA for V2500 HPT Stage 1 Blade
Chromalloy secures FAA PMA for a V2500 HPT Stage 1 blade, its fifth V2500 part certified with Lufthansa Technik.

Chromalloy has secured Federal Aviation Administration (FAA) certification for a new High Pressure Turbine (HPT) Stage 1 blade for the V2500 Select engine, an approval backed by a manufacturing and development investment exceeding $100 million in Florida.
Announced in a company press release on September 22, 2026, the Parts Manufacturer Approval (PMA) marks the fifth V2500 component developed through a strategic agreement between Chromalloy and Lufthansa Technik. The certification introduces a cost-efficient, FAA-approved aftermarket replacement option for operators of the V2500 engine worldwide, breaking the original manufacturer’s exclusivity on the high-value airfoil.
Manufacturing expansion and production ramp-up
To support the new HPT Stage 1 blade, Chromalloy directed more than $100 million into its design, development, and certification processes, alongside a significant expansion of its manufacturing footprint. The production operations span three Florida locations: Tampa, Oldsmar, and Palm Beach Gardens. These facilities handle the complete manufacturing lifecycle of the blade, including smelting, casting, machining, and specialized coating.
Production of the new turbine blades is currently ramping up and will continue to accelerate through the remainder of 2026 and into 2027. The first shipments are slated for launch customer Lufthansa Technik, which employs approximately 23,000 people and serves as a major maintenance, repair, and overhaul (MRO) provider for global airline fleets.
Sebastian Hagenmueller, Head of Product V2500 Overhaul at Lufthansa Technik, stated that the FAA approval represents a critical milestone in the collaboration between the two companies. He noted that each new approval adds a proven and cost-efficient option for their customers operating V2500 fleets.
Expanding the V2500 aftermarket portfolio
The HPT Stage 1 blade certification builds on a foundation of recent regulatory approvals for Chromalloy. On February 10, 2026, the company achieved FAA approval for the V2500 Select 8th Stage Compressor Blade PMA. Chromalloy recently marked its 75th anniversary of operations on August 24, 2026, and has developed more than 60 gas-path PMA parts that have collectively accumulated over 6 billion part flight hours.
Chromalloy Chief Executive Officer Chris Celtruda emphasized the technical rigor required to bring the new blade to market.
“This fifth approval reflects significant engineering investment and the strength of our relationship with Lufthansa Technik. Chromalloy remains at the forefront of innovative aftermarket solutions for high-value engine airfoil applications, and we’re proud to keep expanding the value we deliver to Lufthansa Technik, our launch customer, and other airline operators and MROs across the globe.”
AirPro News analysis
We note that the continued expansion of PMA parts for mature engine programs like the V2500 provides critical leverage for MRO providers and airlines seeking to manage lifecycle costs. High-pressure turbine blades operate in the most extreme thermal and mechanical environments within a gas turbine engine, making their development and certification exceptionally rigorous. By investing heavily in domestic manufacturing capabilities across Florida, Chromalloy is positioning itself to capture significant aftermarket share at a time when original equipment manufacturer supply chains remain constrained. The partnership with a major MRO like Lufthansa Technik ensures a built-in launch customer and validates the technical acceptance of these alternative parts in the global market.
Sources: Chromalloy Corporate Newsroom
Photo Credit: Lufthansa Technik
MRO & Manufacturing
ST Engineering Wins Hebei Airlines CFM56-7B Engine MRO Deal
ST Engineering signs a two-year exclusive PRSV agreement with Hebei Airlines covering 14 CFM56-7B engines at its Xiamen facility.

ST Engineering has secured a two-year exclusive agreement with Hebei Airlines to provide Performance Restoration Shop Visit (PRSV) services for 14 CFM56-7B engines. The maintenance program, which commenced in September 2026, will be executed at ST Engineering’s aerospace facility in Xiamen, China.
Announced in a press release on September 23, 2026, the contract reinforces ST Engineering’s position as a primary Maintenance, Repair, and Overhaul (MRO) provider in the Chinese aviation market. The agreement highlights the sustained demand for CFM56 engine maintenance as operators maintain high utilization rates for their current-generation narrowbody fleets.
Expanding the Hebei Airlines partnership
The exclusive contract covers 14 CFM56-7B engines, the powerplant for the Boeing 737-800 aircraft operated by Hebei Airlines. The maintenance work will be conducted at ST Engineering’s established facility in Xiamen, leveraging the company’s regional footprint to optimize turnaround times for the Chinese carrier.
Hebei Airlines Deputy General Manager Yang Jun cited the MRO provider’s technical expertise as a key factor in the agreement.
“Built on mutual trust and technical excellence, this programme marks the beginning of a new chapter of closer collaboration, innovation and shared success. As we begin this 14-engine maintenance programme, we look forward to deepening our technical collaboration and strengthening our partnership with ST Engineering.”
Strategic growth in engine MRO
ST Engineering continues to expand its engine services portfolio across the Asia-Pacific region. Tay Eng Guan, Senior Vice President and Head of Engine Services at ST Engineering, noted that the partnership reflects the confidence Chinese operators place in the company to enhance engine lifecycle value and performance.
The Hebei Airlines contract aligns with a broader expansion of ST Engineering’s commercial aerospace support network. On September 23, 2026, the company also announced three multi-year agreements with RTX’s Collins Aerospace. That concurrent deal expands collaboration on aircraft component support, including new repair capabilities for Boeing 787 components and continued lifecycle support for Airbus A320 and Boeing 737 Line Replaceable Units (LRUs).
AirPro News analysis
We view this agreement as a clear indicator of the ongoing reliance on the CFM56 engine family. As supply chain constraints and delivery delays impact the introduction of newer aircraft powered by CFM LEAP and Pratt & Whitney engines, airlines are forced to extend the operational life of their existing Boeing 737-800 and Airbus A320ceo fleets. This dynamic creates a highly lucrative environment for established MRO providers capable of executing complex PRSV programs. ST Engineering’s ability to secure exclusive, multi-year contracts demonstrates the premium operators place on reliable turnaround times and proven technical capability in a constrained maintenance market.
Sources: ST Engineering
Photo Credit: ST Engineering
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