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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.

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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

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MRO & Manufacturing

SeAH Besteel Opens Texas Superalloy Plant in H2 2026

SeAH Superalloy Technologies’ Temple, Texas facility will produce 6,000 tons of nickel-based superalloys annually starting H2 2026.

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SeAH Besteel Holdings is accelerating its transition into the advanced aerospace materials sector with the upcoming completion of a new nickel-based superalloy manufacturing facility in Temple, Texas. Announced in a June 24, 2026 press release, the production hub operated by U.S. subsidiary SeAH Superalloy Technologies is scheduled to begin operations in the second half of 2026.

The facility represents a strategic pivot for South Korea’s largest special steelmaker to establish a localized supply chain for North American aerospace and defense manufacturers. By positioning production within the Central Texas advanced manufacturing corridor, the company aims to capitalize on industry-wide reshoring initiatives.

Facility specifications and production capabilities

The 45-acre Temple facility will have an annual production capacity of 6,000 tons of specialty materials. Production will focus on master alloys, additive manufacturing (AM) powders, and nickel-based superalloys required for high-stress aerospace applications.

The project stems from a $155.3 million total investment approved by the SeAH Besteel Holdings board in May 2024. The Office of the Texas Governor subsequently announced the facility agreement in July 2024, noting an estimated initial construction cost of $110 million.

Recent hiring activity indicates the plant is nearing operational readiness. According to reporting by BusinessKorea, SeAH Superalloy Technologies completed recruitment for core technical personnel in May 2026. The hiring of metal chemists responsible for alloy composition analysis signaled that the facility’s melting furnace had entered the trial-run stage. SeAH Superalloy Technologies Chief Executive Officer Michael King stated the project remains “on track, on time, and under budget.”

Expanding North American aerospace integration

The Texas hub builds upon the company’s existing footprint in the commercial aviation supply chain. SeAH currently holds aerospace certifications from The Boeing Company, Airbus SE, and Lockheed Martin Corporation.

In December 2025, subsidiary SeAH Aerospace & Defense secured a Long-Term Agreement (LTA) with Boeing to supply high-strength aluminum alloy materials for aircraft fuselages and wings starting in 2026. The localized production capability in Texas is designed to support similar direct-supply pipelines for Original Equipment Manufacturers (OEMs).

A representative for the parent company noted in the press release that the organization is “transcending its identity as a traditional special steelmaker to leap forward as an advanced materials platform driving the future of the global aerospace industry.”

AirPro News analysis

We view SeAH’s physical expansion into Central Texas as a calculated response to the aerospace industry’s broader push for supply chain resilience. OEMs are increasingly prioritizing localized material sourcing to mitigate the logistical vulnerabilities exposed over the past five years.

While SeAH has not officially confirmed contract volumes with specific commercial space operators in its corporate releases, industry analysts widely anticipate the company will supply specialty alloys to major U.S. space entities like SpaceX. The demand for materials capable of withstanding extreme temperatures in orbital and suborbital applications aligns directly with the capabilities of the new Temple facility. Establishing a domestic U.S. footprint is often a prerequisite for securing sensitive defense and space contracts, positioning SeAH to compete directly with established North American alloy producers.

Sources: SeAH Besteel Holdings

Photo Credit: SeAH Besteel Holdings

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MRO & Manufacturing

MT-Propeller Earns FAA STC for Piper PA-28 Composite Propeller

MT-Propeller receives FAA STC SA04463NY for its MTV-9-B/198-52 propeller on Piper PA-28-235 and PA-28-236 aircraft.

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MT-Propeller Entwicklung GmbH has secured Federal Aviation Administration (FAA) Supplemental Type Certificate (STC) SA04463NY, authorizing the installation of its three-blade natural composite propeller on Piper PA-28-235 Cherokee Pathfinder and PA-28-236 Dakota aircraft. The certification, issued on June 2, 2026, allows operators to upgrade to the MTV-9-B/198-52 propeller system for measurable gains in climb and cruise performance.

Announced in a company press release in June 2026, the FAA approval follows the European Union Aviation Safety Agency (EASA) STC 10062339 R1, which was granted for the same installation on August 15, 2025. The upgrade applies specifically to airframes powered by Lycoming O-540-B1B5 or O-540-B4B5 engines.

Performance and design specifications

According to MT-Propeller Vice President Martin Albrecht, the three-blade installation delivers an approximate 5 percent enhancement in climb performance under Maximum Takeoff Weight (MTOW), Sea Level, and International Standard Atmosphere (ISA) conditions. Cruise speeds also see an increase of two to three knots at MTOW and ISA conditions.

The MTV-9-B/198-52 features natural composite blades designed for vibration damping, resulting in nearly vibration-free operation. The manufacturer notes the blades have no life limitation and are repairable following foreign object debris (FOD) damage. Additionally, the blades incorporate bonded stainless steel leading edges to provide erosion protection. The installation also yields significant reductions in both internal and external noise levels.

Corporate expansion and market footprint

The recent FAA certification adds to MT-Propeller’s portfolio of more than 230 STCs worldwide, with over 34,500 of the company’s systems currently in service. The German manufacturer has been actively expanding its operational footprint to support this growing market presence.

In April 2026, the company established MT-Propeller Canada Inc., a joint venture with AMK Aviation Inc. based in Murillo, Ontario, aimed at improving sales and field support for North-American operators. Concurrently, MT-Propeller expanded its headquarters in Atting, Germany, opening three new production facilities totaling approximately 8,000 square meters (86,000 square feet) to increase manufacturing and service capacity.

AirPro News analysis

The continued rollout of composite propeller STCs for legacy general aviation airframes like the Piper PA-28 series highlights a sustained market demand for modernization. For operators of older aircraft, upgrading to a modern three-blade composite system often represents a cost-effective method to extract better performance and reduce cabin fatigue without the expense of a full engine upgrade or airframe replacement. We view MT-Propeller’s concurrent expansion of its North American support network as a necessary step to sustain its aggressive STC development strategy in the United States and Canada.

Sources: MT-Propeller Entwicklung GmbH, Federal Aviation Administration

Photo Credit: MT-Propeller

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MRO & Manufacturing

Neptune Aviation Takes Delivery of First Airbus A319 Airtanker

Neptune Aviation Services receives its first A319 in Alabama, beginning an 18-month conversion for wildland firefighting deployment in 2028.

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Neptune Aviation Services has taken delivery of its first Airbus A319 at Commercial Jet’s maintenance facility in Dothan, Alabama, marking the start of an 18-month conversion process to transform the commercial airliner into a next-generation wildland firefighting airtanker.

Announced in a press release on June 24, 2026, the delivery initiates a fleet transition for the Missoula, Montana-based operator. Neptune plans to replace its current fleet of BAe 146 aircraft with the A319, aiming for initial operational deployment during the 2028 wildfire season.

Transitioning to the Airbus A319 platform

The selection of the Airbus A319 follows a two-year evaluation period by Neptune to identify a successor to the BAe 146. The new platform will increase the operator’s minimum retardant capacity to 4,500 gallons, a significant upgrade from the 3,000-gallon maximum capacity of the BAe 146. The A319 will also provide increased fuel load and higher cruise speeds, enabling faster response times and extended duration over active fire zones.

Engineering and design work is already underway. Neptune recently completed the Critical Design Review for the conversion in partnership with Aerotec & Concept, a France-based engineering firm. With major design decisions finalized, engineers are currently developing the manufacturing drawings required for the structural modifications.

“The arrival of our first A319 culminates years of planning within Neptune and collaboration with valued partners to ensure we remain at the forefront of aerial firefighting,” stated Jennifer Draughon, President of Neptune Aviation Services. “As wildfire threats grow in size and complexity, we are investing in the next generation of airtankers to continue to deliver the capabilities expected by our agency partners and the communities we protect.”

Conversion timeline and testing phases

The physical conversion of the aircraft will take place at Commercial Jet’s 400,000-square-foot maintenance facility in Alabama. The modification process is expected to take 18 months, placing completion in late 2027 or early 2028.

Before heavy modifications begin, Neptune plans to conduct initial test flights of the unmodified A319 in the coming weeks. These flights will establish baseline performance metrics that will inform the subsequent engineering work.

Nic Lynn, Vice President of Operations for Neptune Aviation Services, emphasized the importance of having the physical airframe on hand to advance the program.

“The acquisition of our first A319 is a pivotal moment for our organization and the wildland firefighting industry,” Lynn said. “The upgrade of our airtanker fleet is fully underway. We have a physical aircraft available that we can convert for aerial firefighting. Our team can start performing test flights, and we can start zeroing in on completing the modifications that must be made to have the aircraft ready for 2028.”

AirPro News analysis

We view Neptune’s transition to the Airbus A319 as a logical progression in the aerial firefighting sector, which has increasingly relied on converted narrowbody commercial aircraft to meet the demands of longer and more intense fire seasons. The BAe 146 has served operators well due to its short-field performance and four-engine redundancy, but aging airframes and limited payload capacities necessitate modernization. By adopting the A319, Neptune secures a platform with a robust global supply chain, widespread parts availability, and modern avionics, which should translate to higher dispatch reliability when fire activity peaks.

Sources: Neptune Aviation Services

Photo Credit: Neptune Aviation Services

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