This 353-pound thrust class turbojet engine is China's first to be completely 3D-printed and flight-validated.CGTN
The state-owned Aero Engine Corporation of China (AECC) has announced that a domestically developed, ultra-lightweight miniature turbojet engine, built primarily with 3D printing, has completed its first single-engine flight test.
This achievement marks a step for China’s independent development of aviation propulsion systems. It validates a manufacturing pathway that uses digital design and additive manufacturing to create engines.
This latest test follows the engine’s initial captive-carry flight test conducted in July of this year. At that time, the engine operated up to a maximum altitude of 4,000 meters (13,000 feet).
Now, the completion of a solo flight moves the technology from a controlled test-bed scenario to an operational application.
High-altitude validation
During the test, the miniature engine powered a target drone for a 30-minute flight. In that time, it reached a maximum altitude of 6,000 meters and a speed of Mach 0.75, which is 75 percent of the speed of sound.
According to the AECC, the engine operated “normally and stably” throughout the entire flight profile. This performance demonstrates the engine’s reliability at higher altitudes and in more complex, dynamic environments than it had previously faced.
The solo flight validated the engine’s design and tested its compatibility and integration with the aircraft’s systems. The state-owned corporation noted the test results will inform future applications for the technology.
This engine is China’s first flight-validated turbojet in the 160-kilogram (353-pound) thrust class to be produced using a combination of 3D printing and multi-disciplinary topology optimization.
Topology Optimization (TO) is a mathematics-based design method used in the process. Using computational models, engineers can determine the most efficient distribution of material within a defined space, given the operational loads, pressures, and constraints the part will face. This process dictates an optimal shape to ensure performance, such as stiffness, is achieved with minimal material, thereby reducing weight.
The resulting intricate, web-like, and lightweight structures are frequently difficult or impossible to produce using traditional manufacturing methods like casting and forging.
This is where 3D printing (additive manufacturing) is used. It allows engineers to fabricate these complex geometries, layer by layer, directly from the digital model. The AECC confirmed that all rotating parts and components—which account for over three-quarters of the engine’s total weight—are 3D-printed.
This combined approach has reduced the total number of parts in the engine, which in turn lowers its overall weight and simplifies its operation and future maintenance requirements.
This successful flight validation provides a basis for future tests, which will target even higher altitudes and greater speeds.
By integrating topology optimization with 3D printing, the AECC is developing a new manufacturing pathway. This method presents a viable alternative to conventional industrial processes that have been a challenge for China’s aerospace sector.
The application of this new design and manufacturing approach is expected to shorten the development cycle for future engines. This acceleration could advance progress in development and manufacturing of high-tech aviation propulsion systems.
