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GKN Aerospace Expands Additive Manufacturing Operations in the US

GKN Aerospace Expands Additive Manufacturing Operations in Connecticut
GKN Aerospace is advancing its manufacturing capabilities in the United States with a significant expansion of its Newington, Connecticut facility. The company is establishing a new production line dedicated to the additive manufacturing of the fan case mount ring (FCMR), a vital component for Pratt & Whitney’s geared turbofan (GTF) engine, which powers aircraft such as the Airbus A220 and Embraer E195-E2. This expansion is anticipated to generate new employment opportunities and strengthen GKN Aerospace’s presence in the US aerospace sector.
Scaling Production and Technological Innovation
The FCMR program represents the largest flight-critical additive component to have received Federal Aviation Administration (FAA) certification, with full serial production expected by the end of 2025. Currently, the core structure of the component, known as the additively manufactured “hot size ring,” is produced at GKN Aerospace’s facility in Trollhättan, Sweden, with final machining performed in Newington. The Connecticut expansion will facilitate a significant increase in production capacity to meet rising market demand.
GKN Aerospace employs a proprietary additive manufacturing process that reduces material consumption, shortens production lead times, and achieves over 70% material savings. This innovative approach not only enhances manufacturing efficiency but also contributes to supply chain resilience by providing an alternative production method amid ongoing industry challenges.
Joakim Andersson, President of Engines at GKN Aerospace, emphasized the strategic importance of the expansion, highlighting the combination of local support, skilled workforce, and aerospace infrastructure as key enablers for scaling additive fabrication technology to industrial levels. Andersson noted that the initiative supports job creation and reinforces the company’s long-term partnership with Pratt & Whitney, while delivering tangible benefits in sustainability, lead times, and production predictability.
Sébastien Aknouche, Senior Vice President of Material Solutions at GKN Aerospace, added that the company currently produces approximately 30 FCMR units per month in Sweden. The transfer and expansion of this advanced technology to the US will consolidate full-volume production in one location and enable the company to broaden its additive manufacturing offerings to additional customers within the American market.
Challenges and Industry Implications
Despite the promising outlook, GKN Aerospace faces several challenges in scaling its US operations. These include navigating complex regulatory requirements, integrating advanced additive manufacturing technologies with existing production systems, and managing evolving supply chain logistics. Successfully addressing these factors will be critical to maintaining quality standards and operational efficiency.
Industry analysts suggest that GKN Aerospace’s investment may stimulate increased interest among investors in aerospace companies leveraging additive manufacturing technologies. Competitors such as GE Aerospace and Toyota are expected to intensify their efforts in this domain, potentially accelerating strategic investments and partnerships with technology providers like Stratasys.
GKN Aerospace currently operates two facilities in Connecticut—Newington and Cromwell—employing over 450 people statewide. This latest expansion follows a US$50 million investment announced in 2024 aimed at advancing sustainable additive manufacturing for both civil and military engine platforms, underscoring the company’s commitment to innovation and customer service.

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