First 3D-Printed Air-Air Heat Exchanger to Take Flight on Cessna Denali

Rendering of the Advanced Turboprop Engine. (Image courtesy of GE.)

The aerospace industry will soon see the deployment of a 3D printed air-air heat exchanger. The component, an industry-first for additive manufacturing, is a vital part of the air conditioning system that maintains the inflight atmosphere for passengers. The new Cessna Denali single engine turboprop plane will be the first aircraft to incorporate this technology.

In 2016, the first 3D printed aircraft was unveiled at the Berlin Airshow, measuring less than 4 meters (13.1 feet) in length and weighing 21kg (46.3 lbs.). What could easily have been dismissed as a model actually represented significant advancements in aerospace technology using additive manufacturing.

The first 3D printed aircraft parts were introduced in 2016 for GE’s CFM LEAP engine design, which includes 19 additively manufactured fuel nozzles.

The announcement of Unison Industries’ additively manufactured air-air heat exchanger is the most recent example of how 3D printing is shaping the aerospace industry.

Cessna Denali single engine turboprop. (Image courtesy of Textron Aviation.)

Giovanni Spitale, president of Unison Industries, confirmed that this is merely the start of a paradigm shift in aircraft innovation, noting: “The air-air heat exchanger is just the beginning – we are investing heavily in additive technology.”

According to Unison, additive manufacturing technology will improve functionality in three key areas: reliability, size/weight and the ability to conform to the intended application.

In the case of the air-air heat exchanger, additive manufacturing will increase reliability by eliminating brazen joints while offering the key benefits of lowered weight and volume without compromising function.

The Denali single engine plane, powered by GE Aviation’s Advanced Turboprop Engine, is targeted to take flight with the additively manufactured air-air heat exchanger in 2018.

For more information, visit the Unison Industries website.