A3D and Innovaero to develop 3D printed turbine engine

Perth-based companies Aurora Labs Limited and Innovaero Pty Limited will collaborate to develop a 3D printed gas turbine for aerospace applications. The first use for it will be in an Innovaero Uncrewed Air System (UAS), the recently launched OWL-X. EX² understands the aim is to license an existing off the shelf engine for Phase 1 development of OWL-X rather than develop an all-new power unit.

Aurora Labs Limited (also known as A3D) is a leading industrial 3D printing company and has signed a Memorandum of Understanding (MoU) with Innovaero. The collaboration aims to leverage Innovaero’s expertise in aerospace systems development and Aurora Labs’ 3D printing capabilities to innovate and enhance the manufacturing of metal UAS components. Aurora Labs’ 3D printed micro gas turbines will be provided for testing on Innovaero’s current UAS platforms.

Last week Innovaero announced it had won an Australian Army Innovation Day 2023 contract to develop a counter-UAS system known as the OWL-X which will be powered by a small, disposable gas turbine jet engine.

Innovaero, now a JV between Aerovation Technologies Pty Ltd and BAE Systems Australia Pty Ltd, has extensive capability designing, manufacturing and certifying products for the aviation industry. Known for its cutting-edge OWL loitering munitions and developers of both the Nearmap Ltd and Spookfish Ltd camera systems, Innovaero will work with Aurora Labs to apply advanced manufacturing to the emerging field of 3D printing for UASs in Australia.

The MoU will see both Companies exchange information regarding printing and aerospace technologies to assess and improve the performance, reliability and productivity of parts printed for UASs, alongside collaborating on Aurora Lab’s Micro Gas Turbine propulsion system. The MoU will run for two years and automatically extends unless terminated by either Party.

 “This is an exciting opportunity for Innovaero to collaborate with A3D to explore a range of possible solutions for micro-turbine propulsion in real-world applications,” commented Innovaero Managing Director Mike von Bertouch. “Additionally, other allied opportunities in the aerospace domain may present pathways for future exploitation with the unique additive manufacturing processes developed by A3D. Innovaero welcomes the opportunity to work with A3D in road testing those opportunities.”

 “A3D is delighted to engage in this MoU with Innovaero,” said A3D’s CEO Rebekah Letheby. “The application of Aurora Labs’ 3D metal printing technology to various UAS platforms presents a significant opportunity to accelerate the development and market introduction of quality UAS components and micro gas turbine propulsion systems. By integrating our components at this early stage in our development, we can better understand and optimise the performance of printed parts, likely paving the way for advancement in technology and performance of these UASs and propulsion systems.

The collaboration between Aurora Labs and Innovaero highlights ability to create complex, high-performance parts through 3D metal printing. This offers significant advantages in terms of design flexibility, material efficiency, and production speed. By utilising Aurora Labs advanced 3D printing technology, Innovaero can produce lightweight, durable UAS components that are optimised for performance and reliability, enhancing overall performance capability.

Moreover, integrating and providing micro gas turbines via 3D printing holds promise for both UAS and broader aerospace applications. Aurora Labs’ ability to produce complex micro gas turbine parts with enhanced performance characteristics will support Innovaero in developing more efficient operational flights with state-of-the-art propulsion systems made in Australia.