Pratt & Whitney eyes Additive Manufacturing to maintain F-22 engines following $1.5 billion contract
February 27, 2025
US defence contractor Pratt & Whitney, an RTX business, headquartered in East Hartford, Connecticut, USA, has secured a three-year contract valued up to $1.5 billion to sustain the F119 engines that power the US Air Force’s F-22 fighter jets.
The contract will improve readiness and reduce costs for a fleet of more than 400 engines that have reportedly accumulated over 900,000 flight hours.
In a conference call, Caroline Cooper, Pratt & Whitney’s executive director for the F119, said that the company is pursuing Additive Manufacturing for F119 parts. “We see real value in additive, not only to help simplify the supply chain, but also reduce production time and cost while leading to increased readiness,” Cooper said. Pratt & Whitney has already explored using additive production for F135 parts and is now expanding that to the F119, she added.
The F-22 Raptor’s two F119 engines generate over 35,000 pounds of thrust, enabling altitudes above 65,000 feet with unmatched speed and agility. Unlike many fighter jets, the F-22 can achieve and maintain supersonic speeds without afterburners, a strategic feature known as supercruise that conserves fuel and extends operational range.
Pratt & Whitney has lowered costs on its F119 engines through its ongoing Usage Based Lifing programme, which leverages real-time data to enhance maintenance efficiency and extend engine life, while also improving the engine’s kinematic performance with an engine control schedule update. This latest contract is intended to continue this readiness and cost savings efforts with a focus on safety, availability, simplicity of maintenance, and modernisation initiatives.
“The F119’s readiness and reliability rates have never been more important, and we are improving both while lowering lifecycle costs,” added Jill Albertelli, president of Military Engines at Pratt & Whitney. “We are committed to helping our US Air Force customer maintain the F-22’s combat edge.”
