Advancing UK Aerospace, Defence, Security & Space Solutions Worldwide
  • Home
  • /
  • Aerospace
  • /
  • Rolls-Royce starts manufacturing world’s largest fan blades

Aerospace

Rolls-Royce starts manufacturing world’s largest fan blades

Rolls-Royce has started manufacture of the world’s largest fan blades, for its UltraFan demonstrator engine that will set new standards in efficiency and sustainability.

Above: An artist’s impression of the UltraFan demonstrator.
Courtesy Rolls-Royce

As a set the composite blades have a 140-inch diameter, which is almost the size of a current narrowbody fuselage, and are being made at the company’s technology hub in Bristol, UK. The milestone also marks the official start of production of parts for the demonstrator.

Advertisement
ODU RT

UltraFan will set new standards in efficiency and sustainability, offering a 25% fuel reduction compared to the first generation of Trent engine, and deliver the same percentage reduction in emissions.

Part of that efficiency improvement comes from UltraFan’s composite fan blades and fan case, which reduce weight on a twin-engine aircraft by 700kg, the equivalent of seven people travelling “weight free”.

Chris Cholerton, Rolls-Royce, President – Civil Aerospace, said: “This is the decade of UltraFan and it’s exciting to enter the 2020s with the start of production of the demonstrator engine. We have got all the building blocks in place, the design, the technologies, a brand-new testbed, and now we are actually seeing the engine come together.”

UltraFan, which will start ground tests in 2021 and be available towards the end of this decade, is a scalable design from 25,000lb all the way up to 100,000lb. It also features:

  • A new engine core architecture – to deliver maximum fuel burn efficiency and low emissions
  • Advanced ceramic matrix composites – heat resistant components that operate more effectively in high turbine temperatures
  • A geared design to maximise high-thrust, high-bypass ratio engine efficiency

UltraFan is a key element of Rolls-Royce’s sustainability strategy, which involves continual research to improve gas turbine performance as well as pioneering electrification and working with industrial partners to accelerate the incorporation of Sustainable Aviation Fuels.

Advertisement
Gulfstream RT

It is also part of the Rolls-Royce IntelligentEngine vision, which brings together its products, services and digital technology.

The fan blades are created through the build-up of hundreds of layers of carbon-fibre materials, pre-filled with state-of-the-art, toughness-enhanced, resin material. Heat and pressure are then applied, and each blade is finished with a thin titanium leading edge, which offers extreme protection against erosion, foreign objects and bird strikes.

Composite blades have already been extensively tested on an Advanced Low Pressure System development engine, including in-flight testing on the Rolls-Royce Flying Test Bed.

ALPS is a partnership between Rolls-Royce, Clean Sky, Innovate UK, BEIS, ATI, ITP Aero and GKN. The portfolio of technologies being developed to enable UltraFan is supported by ATI, Innovate UK, LuFo and Clean Sky 2.

 

 

Advertisement
Babcock LB
Flights increase as summer hots up

Aerospace

Flights increase as summer hots up

18 July 2025

UK air traffic in June increased by 2.5% on the same month last year as NATS, the UK’s major provider of air traffic services, safely handled 237,215 flights, up more than 2,600 on May.

ZeroAvia granted patents for hydrogen-electric engine development

Aerospace

ZeroAvia granted patents for hydrogen-electric engine development

17 July 2025

ZeroAvia today announced it has been awarded nine new patents this year so far, with many critical to the company’s roadmap for scaling hydrogen-electric engines for large regional aircraft.

BBGA co-hosts Isle of Man Aviation Conference

Aerospace

BBGA co-hosts Isle of Man Aviation Conference

17 July 2025

For the first time, the British Business General Aviation Association (BBGA) joined Martyn Fiddler as joint hosts of the 13th Isle of Man Aviation Conference, bringing together 120 business aviation delegates at Douglas’ Villa Marina venue.

Flying to become more accessible for disabled people

Aerospace

Flying to become more accessible for disabled people

16 July 2025

An industry and consumer expert group, tasked by the UK Government to advise on how to make flying more accessible for disabled people, has unveiled its suite of recommendations today.

Advertisement
DSEI 2025
Doncasters expands Groton site with new shell line

Aerospace

Doncasters expands Groton site with new shell line

15 July 2025

Doncasters today announced the successful commissioning of a brand-new, fully automated shell line, at its Groton facility in the US - a major milestone within its 2025 Performance Improvement Plan and a key advancement in the company’s long-term manufacturing strategy.

ZeroAvia and Horizon Aircraft to explore hydrogen eVTOL propulsion

Aerospace

ZeroAvia and Horizon Aircraft to explore hydrogen eVTOL propulsion

15 July 2025

ZeroAvia and Horizon Aircraft today announced plans to work together on developing regional hydrogen-electric VTOL air travel.

Advertisement
DSEI 2025