China has tested a fully 3D-printed miniature turbojet propulsion unit under real flight conditions for the first time. The successful test flight took place in Inner Mongolia and reached an altitude of up to 4,000 meters. The engine was developed by the Aero Engine Corporation of China (AECC).
The jet engine is the first of its kind in China with a thrust of 160 kilograms to be manufactured entirely using an additive process. AECC relied on a combination of multi-disciplinary topology optimization and 3D printing. This process enables the targeted reduction of material in areas subject to less stress, resulting in significant weight savings.
In addition to structural optimization, an integrative design of the components was also carried out. The elimination of conventional production steps enabled simplified assembly and improved thermal and aerodynamic properties. The result is a compact, lightweight drive with optimized performance figures.
Before the flight test was carried out, the engine underwent extensive ground tests. Among other things, the developers tested the thermal stability, thrust performance and mechanical load capacity over the entire life cycle. All relevant operating parameters remained within the specified tolerances.
With the successful test flight, China has closed a technological gap in the production of small turbojet engines using additive processes. According to the AECC, the project forms an important basis for future developments in the field of modern aircraft engines. It shows that additive manufacturing can be used not only for prototypes, but also in the highly stressed area of engine technology.
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