GE Aerospace has received US Federal Aviation Aviation certification for its 3D printing-enabled Catalyst turboprop engine.
GE announced previously that approximately 30% of Catalyst's parts are 3D printed, 855 conventionally manufactured components were reduced to just 12 3D printed titanium parts.
GE’s state-of-the-art, clean-sheet turboprop design boasts a 16:1 overall pressure ratio, delivering impressive performance gains. According to reports, it achieves 18% better fuel efficiency and up to 10% more cruise power compared to competing engines. As part of GE Aerospace’s next-generation engine lineup, the Catalyst is manufactured at the company’s Avio Aero facilities across Italy, the Czech Republic, Poland, and Germany.
GE Aerospace highlights that the Catalyst is the first turboprop to be certified under the FAA’s latest regulations, incorporating more than 20 new requirements. The FAR Part 33 certification process involved 23 Catalyst engines, accumulating over 8,000 hours of operation and undergoing more than 190 component tests.
The Catalyst turboprop engine incorporates advanced technology, including two stages of variable stator vanes and cooled high-pressure turbine blades. Additive manufacturing has played a key role in its development, reducing weight by approximately 100 lb (45.4 kg) and streamlining maintenance by minimizing the number of components.
A standout feature of the Catalyst is its full authority digital engine control (FADEC) system, which allows pilots to operate the aircraft using a single lever—unlike traditional turboprops that require three. This innovation simplifies flight operations, making the experience more comparable to that of a jet.
Looking ahead, the fully certified Catalyst will power Textron Aviation’s new Beechcraft Denali turboprop aircraft. Textron selected GE Aerospace’s 3D-printed propulsion system in 2015 when it was known as the Advanced Turboprop (ATP) engine. By 2018, the engine had successfully completed a test fire at a GE Aviation facility near Prague, Czech Republic.
Beyond commercial aviation, the Catalyst will also be integrated into the Eurodrone, an unmanned aerial vehicle (UAV) jointly developed by Airbus, Dassault Aviation, and Leonardo. Designed as a twin-engine reconnaissance aircraft, the Eurodrone has already secured orders from NATO countries, including France, Germany, Italy, and Spain.
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