GKN Aerospace Expands Connecticut Facility with Additive Manufacturing Line for Fan Case Mount Ring to Support Pratt & Whitney GTF Engine Programme!

GKN Aerospace has announced a major expansion of its Newington, Connecticut, USA, facility with the addition of a new production line dedicated to Additive Manufacturing (AM) of the Fan Case Mount Ring (FCMR), a critical component of the Pratt & Whitney GTF engine that powers aircraft such as the Airbus A220 and Embraer E195-E2. The move reinforces GKN Aerospace’s commitment to advancing industrial-scale additive fabrication in the United States, while also creating new employment opportunities and strengthening its long-standing relationship with Pratt & Whitney.

The FCMR programme represents a groundbreaking achievement in aerospace engineering as the largest flight-critical additively manufactured component to secure FAA certification. With 100% serial production expected by the end of 2025, the expansion in Connecticut will be instrumental in meeting rising demand. Currently, approximately 30 FCMR units per month are being produced at GKN Aerospace’s Trollhättan facility in Sweden, where the core “hot size ring” is additively fabricated before being shipped to Newington for final machining.

“Today we already produce around 30 FCMR units per month at our Trollhättan facility,” explained Sébastien Aknouche, Senior Vice President, Material Solutions at GKN Aerospace. “Expanding our cutting-edge technology, developed in Sweden, to the US will support the full volume of FCMR production in one place. As well as ramping up our production for the FCMR, it will also enable us to expand our additive fabrication offering to other customers in the USA.”

The construction of the new production line is already underway, with strong support from the Connecticut Department of Economic and Community Development and the Connecticut Governor’s Office. GKN Aerospace currently operates two facilities in Connecticut — Newington and Cromwell — employing more than 450 people across the state. This latest investment will bolster the state’s position as a hub for advanced aerospace manufacturing while deepening GKN’s footprint in the US market.

Joakim Andersson, President Engines, GKN Aerospace, emphasized the significance of the development, stating: “This expansion in Connecticut marks a major milestone for GKN Aerospace and our Fan Case Mount Ring programme. The combination of strong local support, the highly skilled workforce and the availability of an aerospace network and infrastructure here allows us to bring our latest additive fabrication technology into industrial-scale production, creating jobs and supporting our long-term relationship with Pratt & Whitney. We are proving that additive fabrication is not only technically transformative but also delivers real-world benefits in sustainability, lead-time and predictability for our customers.”

Beyond capacity expansion, GKN Aerospace highlights that its AM technology brings transformative advantages to aerospace production. The process significantly reduces raw material consumption, shortens production lead times, and is projected to deliver over 70% material savings compared to traditional manufacturing methods. These benefits not only enhance cost efficiency and predictability for customers but also support broader sustainability goals by reducing waste and improving supply chain resilience.

With the Connecticut expansion, GKN Aerospace is positioning itself as a leader in scaling additive manufacturing for aerospace applications. By localizing advanced production capabilities and integrating cutting-edge technologies, the company aims to set new benchmarks for performance, sustainability, and reliability in the aerospace supply chain.