GE Aerospace Catalyst Turboprop: FAA Certification for New Engine with Additive Manufacturing

GE Aerospace has announced that the Catalyst turboprop engine has been certified by the U.S. Federal Aviation Administration (FAA) under FAR Part 33. The certification process included tests on over 23 engines and more than 190 individual components. During the evaluation, the test engines accumulated over 8,000 operating hours to demonstrate compliance with the defined performance targets.

Riccardo Procacci, President and CEO, Propulsion and Additive Technologies at GE Aerospace said, “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. We are now fully committed to supporting the production ramp-up of the engine towards the entry into service in support of our customers.”

The engine features an overall pressure ratio of 16:1 and offers up to 18% lower fuel consumption and up to 10% higher cruise power compared to other engines in its class. Key innovations include two-stage variable stator vanes and cooled high-pressure turbine blades. A significant portion of the components is produced using additive manufacturing, which enables optimized weight distribution and improved aerodynamic properties.

Paul Corkery, Catalyst General Manager at Avio Aero said, “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 is part of GE Aerospace’s next generation of propulsion systems. It has been designed and manufactured at various locations across Europe, including Avio Aero in Italy, as well as production facilities in the Czech Republic, Poland, and Germany. With its successful certification, the engine’s market entry is approaching, and it remains to be seen what further advancements will emerge from the combination of turboprop technology and additive manufacturing.