Rolls-Royce breaks additive record with printed Trent-XWB bearing

Rolls-Royce has produced the largest ever civil aero engine component using 3D printing. Working with the Manufacturing Technology Centre (MTC) in Coventry, which last week opened its new National Centre for Additive Manufacturing  and Aerospace Research Centre, the British company printed the front bearing for a Trent XWB-97 engine, which is made from titanium and 1.5m across — about the size of a tractor tyre.

The component was not made in a single piece; it contains 48 aerofoil-shaped  vane components, which were also made by additive manufacturing. The project also involved Sheffield University and 3D printing specialist Arcam, whose electron-beam machines were used to build the vanes. ”One of the things that was key to us is the MTC can analyse the powders — the core building material — manufacture the part and provide the analysis so we can assess the parts’ integrity before we assemble the component,” commented Clive Grafton-Reed, head of laser processes at Rolls-Royce. “This has given us a good understanding of how we can recycle powder, which is core for the business case of the process, and how to classify flaws in the process.”