EAST HARTFORD, CT—Pratt & Whitney has introduced a cutting-edge additive manufacturing repair process that significantly reduces turnaround time for GTF engine components—cutting process time by more than 60%. Developed at the company's North American Technology Accelerator in Jupiter, Florida, the new technique uses Directed Energy Deposition (a form of 3D printing) to restore structural case features.

This innovation is expected to save Pratt & Whitney $100 million over five years by recovering parts through more efficient repairs. It also minimizes the impact of material supply constraints, lowers tooling costs, and streamlines setup and machine changeovers.

The new process was created in collaboration with the Connecticut Center for Advanced Technology and the RTX Research Center. Pratt & Whitney is now working to industrialize and scale this solution across its global GTF MRO (maintenance, repair, and overhaul) network, which includes 20 shops across four continents.

This initiative aligns with the company’s broader accelerator strategy announced in April 2024, which includes expanding digital inspection, adaptive processing, and coating technologies. Together with its Singapore-based accelerator, the program is projected to save at least $24 million annually.