F-35 Engine Case Gets 3D‑Printed Makeover – First Full‑Scale Test by 2028

In a move that feels straight out of a science‑fiction novel, Pratt & Whitney has joined forces with GKN Aerospace to see whether a 3‑D‑printed metal case can replace the traditional, forged housing that wraps the F‑135 engine of the F‑35 Lightning II. The plan isn’t just a lab exercise – the goal is a certified, flight‑ready component by the end of 2028.

The two companies will first roll out a full‑scale demonstrator next year, 2027, using GKN’s laser‑directed energy deposition with wire (L‑DEDw) process. This technique spits molten metal layer by layer, building up a part that can be as big as an engine case and, crucially, as precise as a machined one.

What makes this effort interesting is the scope. Additive manufacturing has already proven its worth on tiny brackets and low‑volume parts, but an engine case has to survive blistering temperatures, high‑g loads and razor‑thin tolerances. The team isn’t redesigning the engine; they’re simply swapping the old metal shell for a new one that fits perfectly with the existing F‑135 fleet.

GKN will take the lead from its Kongsberg, Norway, facility, while the Norway Defence Materiel Agency throws its support behind the programme. If the 2027 demonstrator meets the stringent performance and dimensional checks, the next phase will focus on qualification and certification work that runs through 2028.

Why bother? For manufacturers, moving big structural parts to additive processes could shave months off production cycles and cut the waste that comes with traditional subtractive machining. Wire feedstock, in particular, generates far less scrap than carving a part out of a solid billet.

Of course, the real test is whether these theoretical benefits survive the harsh world of military propulsion. The upcoming data will shed light on repeatability, quality‑control and the hoops the aerospace certification authorities will require.

Both firms say the partnership bolsters long‑term sustainment of the F‑135 program and paves the way for future platforms that might rely on similar manufacturing tricks. As GKN’s senior VP Sébastien Aknouche put it, it’s about “industrialising additive manufacturing for demanding aerospace applications.” Meanwhile, Pratt & Whitney’s Chris Johnson frames the work as a key step in the engine’s technology roadmap.

If everything stays on schedule, the F‑35 could soon be flying with an engine case that was born from a digital model and printed in metal – a milestone that could reshape how the defense aerospace supply chain looks for years to come.