STIMULANT · Project

Faster, Cheaper Machining of Critical Jet Engine Parts Without Sacrificing Safety

manufacturingPilotedTRL 6

nottingham.ac.uk

Jet engine parts are made from superalloys — metals so tough they eat through cutting tools. Machining them is painfully slow and expensive because you can't rush it without damaging the surface, and a tiny surface flaw can cause an engine failure. STIMULANT combined three different cutting methods — high-speed machining with heat control, waterjet milling, and laser-guided waterjet cutting — into hybrid processes that remove metal much faster while keeping the surface quality that safety inspectors demand. Think of it like using the right combination of kitchen knives instead of one blade for everything — each cut is faster and cleaner.

By the numbers

hybrid machining methods developed and validated

consortium partners

countries in consortium

phases from standard features to engine-like part demonstration

60%

industry partner ratio in consortium

total project deliverables

The business problem

What needed solving

Machining safety-critical aeroengine parts from superalloys is extremely slow and expensive. These materials resist cutting, destroy tooling, and any surface damage during machining can cause catastrophic fatigue failure in service. Manufacturers are stuck choosing between speed and safety — faster cuts risk surface integrity, while safe cuts kill productivity and drive up unit costs.

The solution

What was built

Three validated hybrid machining processes: heat-controlled high-speed machining, dynamically erosion-controlled waterjet machining, and laser waterjet-guided machining — all demonstrated on engine-like safety-critical parts with verified surface integrity and fatigue performance. The project also developed a Standard Features methodology for mapping these methods to different part families.

Audience

Who needs this

Aeroengine component manufacturers (Safran, MTU, ITP Aero tier suppliers)Aerospace MRO providers machining superalloy turbine partsContract machining shops specializing in hard-to-cut aerospace alloysGas turbine OEMs and their supply chain for power generation componentsMachine tool builders developing hybrid manufacturing platforms

Business applications

Who can put this to work

Aerospace Manufacturing

enterprise

Target: Aeroengine parts manufacturers and MRO providers

If you are an aerospace manufacturer struggling with long cycle times and high tooling costs when machining superalloy turbine components — this project developed 3 validated hybrid machining methods (heat-controlled high-speed, waterjet milling, and laser-waterjet guided) that deliver higher material removal rates on safety-critical parts while maintaining surface integrity and fatigue performance. Demonstrated on engine-like parts across 3 phases.

Precision Engineering

mid-size

Target: Contract machining shops serving aerospace and power generation

If you are a precision machining subcontractor competing on turnaround time for complex superalloy geometries — this project validated controlled-depth waterjet milling and through-cutting for freeform surfaces with high geometrical accuracy. The methods were tested as Standard Features across 3 phases, meaning they can be mapped to your existing part families for cost-efficient adoption.

Power Generation Equipment

enterprise

Target: Gas turbine manufacturers and component suppliers

If you are a turbine component supplier facing rising costs from slow machining of nickel-based superalloys — this project demonstrated hybridised processing routes that combine multiple cutting methods into a single workflow for complex geometry surfaces. With 5 consortium partners including 3 industry players across 4 countries, the methods were validated on representative engine-like parts.

Frequently asked

Quick answers

How much could this reduce our machining costs?

The project targeted a step-change in Material Removal Rates and reduction in production costs for superalloy parts. Specific cost reduction percentages are not published in the available data. Contact the consortium for benchmarking results from Phase 2 and Phase 3 demonstrations.

Has this been tested at industrial scale?

Yes — Phase 3 demonstrated the hybrid machining methods on engine-like safety-critical parts, not just lab coupons. The consortium included 3 industry partners (60% industry ratio) across 4 countries, and the project produced open demonstrators for specialist audiences. This is beyond lab-scale but not yet full production deployment.

What is the IP situation and can we license this?

The project ran under Clean Sky 2 (CS2-IA), which typically means IP is shared between the consortium and the Clean Sky Joint Undertaking. Licensing terms would need to be negotiated with the University of Nottingham as coordinator and the relevant industry partners. Based on available project data, 6 deliverables were produced.

Which materials and part types does this work for?

The methods were developed specifically for safety-critical aeroengine parts made from superalloys. The Standard Features methodology decomposes part families into classes with technical, functional, and economic characteristics, so the approach can be mapped to different part geometries within this material family.

How mature is this technology — can we implement it now?

The project completed all 3 phases through to demonstration on engine-like parts, with open demonstrators produced. This puts it past prototype stage but short of turnkey commercial deployment. You would need adaptation work to integrate these hybrid processes into your specific production line.

What equipment would we need?

The 3 hybrid methods require high-speed machining centers with heat control capability, waterjet machining systems for controlled-depth milling and through-cutting, and laser waterjet-guided cutting systems. Based on available project data, specific equipment specifications would need to be obtained from the consortium partners.

Consortium

Who built it

The STIMULANT consortium of 5 partners across 4 countries (UK, Switzerland, Spain, Sweden) is notably industry-heavy at 60%, with 3 industry players and 2 SMEs alongside the University of Nottingham as coordinator. This composition signals strong commercial intent — the technology was developed with manufacturing end-users at the table, not just academics. The Clean Sky 2 Innovation Action funding scheme further confirms this was aimed at near-market results. For a potential adopter, this means the hybrid machining methods were stress-tested against real industrial requirements, not just optimized for journal publications.

THE UNIVERSITY OF NOTTINGHAMCoordinator · UK
FUNDACION TEKNIKERparticipant · ES
SECO TOOLS ABparticipant · SE

How to reach the team

The coordinator is the University of Nottingham (UK). SciTransfer can facilitate an introduction to the research team.

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

Next steps

Talk to the team behind this work.

Want to know if STIMULANT's hybrid machining methods fit your production line? SciTransfer can arrange a technical briefing with the consortium — contact us for a personalized assessment.

Order a report on this topic More in Manufacturing & Industry 4.0