AOrbit · Project

Test Rig for Next-Generation Aero-Engine Gearbox Bearings That Cut Weight and Boost Reliability

transportPrototypeTRL 4Thin data (2/5)

nottingham.ac.uk

Imagine a jet engine with a massive fan at the front — future engines need a gearbox between the fan and the turbine, much like the gearbox in your car. The bearings inside that gearbox spin under extreme heat and load, and if they fail, the engine fails. AOrbit built a specialized test machine that simulates real flight conditions so engineers can figure out exactly how these bearings behave — and how to make them lighter, tougher, and more reliable before they ever go into an actual aircraft.

By the numbers

€70m

University of Nottingham aerospace research portfolio value

€20m

Clean Sky projects administered by the university

Consortium partners (University of Nottingham only)

Total project deliverables

The business problem

What needed solving

Next-generation geared turbofan aero-engines need lightweight, ultra-reliable journal bearings inside their Power Gear Boxes — but there has been no dedicated test facility to validate bearing performance under realistic orbital motion conditions. Without this data, engine manufacturers risk costly failures during late-stage testing or in service, and bearing suppliers cannot prove their products meet the extreme demands of these future engines.

The solution

What was built

AOrbit delivered a fully assembled test rig that simulates the operating conditions of journal bearings inside a Power Gear Box for future large civil geared turbofan aero-engines. The rig was designed, built, and prepared for commissioning tests, with 2 total deliverables completed.

Audience

Who needs this

Aero-engine OEMs developing geared turbofan engines (e.g., Rolls-Royce, Safran, Pratt & Whitney)Precision bearing manufacturers targeting aerospace gearbox contractsAerospace gearbox and power transmission system suppliersMRO providers preparing for next-generation geared turbofan fleetsLubrication and tribology companies developing aerospace-grade oils and coatings

Business applications

Who can put this to work

Aerospace Engine Manufacturing

enterprise

Target: Aero-engine OEMs and gearbox suppliers

If you are an aero-engine manufacturer developing geared turbofan engines — this project built a test rig that replicates real Power Gear Box conditions for journal bearings. The experimental data helps you validate bearing designs earlier, reducing costly in-engine testing and accelerating certification timelines. The University of Nottingham manages over €70m in aerospace research with partners like Rolls-Royce and Airbus.

Bearing and Tribology Components

mid-size

Target: Precision bearing manufacturers and coating specialists

If you are a bearing manufacturer trying to win contracts for next-generation aero-engine gearboxes — this project generated performance data under representative flight conditions. You can use these validated test methods and data sets to prove your bearings meet the extreme demands of ultra-high bypass ratio engines, giving you an edge over competitors who rely only on generic lab tests.

Aerospace MRO and Certification

enterprise

Target: Maintenance, repair and overhaul service providers

If you are an MRO provider preparing for the next wave of geared turbofan engines — this project provides validated bearing behavior data under realistic operating conditions. Understanding how journal bearings wear and perform in Power Gear Boxes helps you plan maintenance intervals, stock the right parts, and train technicians before these engines enter widespread service.

Frequently asked

Quick answers

What would it cost to access this test rig or its data?

The project does not publish pricing for rig access or data licensing. As a Clean Sky 2 project at the University of Nottingham, access would likely be negotiated through a research collaboration or industrial partnership agreement. Contact the university's aerospace technology team for specific terms.

Can this technology be used at industrial scale?

The test rig itself is a laboratory facility designed to replicate conditions inside a Power Gear Box for future large civil geared turbofan engines. It is not a production tool but a validation instrument — its value at industrial scale lies in the bearing performance data it generates, which directly informs production bearing design and certification.

What is the IP situation and can I license this?

The project was funded under Clean Sky 2 (CS2-IA), which has specific IP rules governing the Joint Undertaking and topic managers. Any licensing of rig design, test methods, or experimental data would need to be negotiated with the University of Nottingham and potentially with the Clean Sky 2 topic leader. Based on available project data, no open licensing is indicated.

How does this compare to existing bearing test methods?

The project explicitly states it goes beyond what was specified in the original call by proposing engineering refinements during experimentation. Unlike generic bearing test rigs, AOrbit simulates the orbital motion specific to Power Gear Box journal bearings in ultra-high bypass ratio engines — a condition that standard test setups do not replicate.

Who are the industry partners involved?

The consortium itself is a single-partner project (University of Nottingham only). However, the university's aerospace portfolio of over €70m includes collaborations with Airbus, Rolls-Royce, Liebherr, Dassault Aviation, Meggitt, and Safran. The project operates within this broader industrial ecosystem, particularly through Clean Sky 2.

What is the timeline for real-world application?

The project ran from March 2017 to June 2021 and delivered a fully assembled test rig. The bearing data generated feeds into longer-term geared turbofan engine development programs. Real-world application depends on the certification timeline of the engines these bearings are designed for, which is driven by the OEMs.

Consortium

Who built it

This is a single-partner project run entirely by the University of Nottingham, with zero industrial partners in the formal consortium. That means there is no built-in commercialization path within the project itself. However, the university's aerospace group manages over €70m in live research with major industry players including Airbus, Rolls-Royce, Liebherr, Dassault Aviation, Meggitt, and Safran, so the informal industry network is strong. For a business looking to engage, you would deal directly with a well-resourced university team experienced in industrial collaboration, but expect academic timescales and IP negotiation rather than a turnkey solution.

THE UNIVERSITY OF NOTTINGHAMCoordinator · UK

How to reach the team

Reach the coordinator through the University of Nottingham Institute for Aerospace Technology — SciTransfer can facilitate introductions.

Order a report on this consortium See THE UNIVERSITY OF NOTTINGHAM profile →

Next steps

Talk to the team behind this work.

Want to access AOrbit bearing test data or explore a research partnership with Nottingham's aerospace team? SciTransfer can arrange a targeted introduction and help you assess the fit.

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