GE Aerospace / Avio Aero Catalyst Turboprop Engine

GE Aerospace / Avio AeroAerospacesince 2025

GE Aerospace / Avio Aero Catalyst Turboprop Engine

Catalyst turboprop engine — 30% AM internal metal parts

Aerospace85% confidence

AEROSPACE · PART PHOTO

Challenge

Designing a clean-sheet, highly efficient turboprop engine for the Beechcraft Denali. Hundreds of conventional parts needed to be made lighter and simpler without compromising reliability or certification compliance.

Solution

Nearly 30% of the Catalyst's internal metal parts are 3D-printed, including fuel heater, exhaust case, and C-sump. Additive consolidation reduced part count dramatically. Engine underwent >8,000 hours of testing across 23 test engines before FAA certification on Feb 27, 2025.

Outcomes

01hundreds of parts consolidated part consolidation

Technologies

Laser Powder Bed Fusion

Source

First modern turboprop with extensive AM content; Beechcraft Denali service entry targeted 2026; production ramp underway

Cite this page

APA

AM Roadmap. (2025). GE Aerospace / Avio Aero Catalyst Turboprop Engine. AM Roadmap (v0.4.2-fixes-deployed). Retrieved 2026-05-17, from https://amroadmap.com/success-stories/ge-catalyst-turboprop-2025

BibTeX

@misc{amroadmap_ge_aerospace_avio_aero_catalyst_turbopro_2025,
  title  = {GE Aerospace / Avio Aero Catalyst Turboprop Engine},
  author = {{AM Roadmap}},
  year   = {2025},
  url    = {https://amroadmap.com/success-stories/ge-catalyst-turboprop-2025},
  note   = {AM Roadmap dataset v0.4.2-fixes-deployed, accessed 2026-05-17}
}

Canonical URL: https://amroadmap.com/success-stories/ge-catalyst-turboprop-2025