GE Aerospace’s Catalyst turboprop engine with additively manufactured parts receives FAA certification
March 4, 2025
GE Aerospace has announced that its Catalyst turboprop engine, featuring a high number of additively manufactured parts, has been certified by the US Federal Aviation Administration (FAA).
Almost 30% of the internal metal parts of the Catalyst engine are reported to be additively manufactured, reducing the total part count from 855 to just 12. The AM parts help shave off more than 45 kg in weight and are produced by Avio Aero, a GE Aerospace company based in Brindisi, Italy.
“The certification of the Catalyst engine is a significant milestone for our company and a proud moment for all our team members who have dedicated their efforts to the design, development, and testing of this brand-new European turboprop engine,” stated Riccardo Procacci, President and CEO – Propulsion and Additive Technologies at GE Aerospace. “We are now fully committed to supporting the production ramp-up of the engine towards the entry into service in support of our customers.”
Additive Manufacturing has helped enable the Catalyst engine to achieve a 16:1 overall pressure ratio, resulting in up to 18% better fuel consumption and up to 10% higher cruise power compared to other engines in the same class. The Catalyst introduces two stages of variable stator vanes and cooled high-pressure turbine blades.
Paul Corkery, Catalyst General Manager at Avio Aero added, “Catalyst has been through a rigorous certification and testing process. We are pleased with the performance of the engine throughout its ground and flight test campaigns, and we remain fully focused on supporting Textron Aviation as they complete the certification process and prepare for entry into service of the Beechcraft Denali.”
The Catalyst engine belongs to the GE Aerospace suite of next-generation engines. It was designed, developed, and manufactured at GE Aerospace sites in Europe, including Avio Aero in Italy, Czechia, Poland, and Germany.
The FAR (Federal Aviation Regulation) Part 33 certification involved testing over twenty-three engines and more than 190 components. During the certification process, the test engines completed more than 8,000 hours of operation, demonstrating and meeting its key performance targets.
