skip to Main Content
Pratt & Whitney, USAF Launch Revolutionary Digital Engine Monitoring Technology

Pratt & Whitney, USAF Launch Revolutionary Digital Engine Monitoring Technology

For the first time in aerospace propulsion history, Pratt & Whitney has launched an innovative Usage-Based Lifing (UBL) program for its F119 5th generation engine fleet, which is expected to save the U.S. Air Force $800+ million over the life of the program – while continuing to maximize readiness.

By digitally combining aircraft flight data with Pratt & Whitney’s state-of-the-art maintenance engineering algorithms, UBL allows the USAF to plan engine maintenance when it’s actually needed – maximizing both warfighting readiness and maintenance cost savings.

Two F119 engines power each F-22 Raptor in the U.S. Air Force’s fleet. When the F-22 reached Initial Operational Capability (IOC) and was declared combat-ready in 2005, the F119 turbofan became the first operational 5th generation fighter engine in history. One of the exceptional performance benefits the F119 gives the F-22 is supercruise, the ability to fly at supersonic speeds without afterburning, which provides the F-22 exceptional combat performance without compromising mission range. In addition to supercruise, the F119 combines stealth technologies, vectored thrust, and high thrust-to-weight performance to provide unprecedented maneuverability and survivability.

Along with performance, sustainment is a critical part of any engine program, as it’s crucial to maintain readiness at high levels and keep costs within budget. For decades, engine sustainment budgeting and planning was completed largely based on historical data and average mission usage metrics. Without full flight data, maintainers can only make assumptions about how the aircraft was flown and is going to fly and those assumptions are applied to every engine without the ability to tailor maintenance to an engine’s specific needs. As a result, engine maintenance might be performed earlier or later than necessary, leading to inefficiencies over the long run.

Incorporating Usage-Based Lifing, however, allows the operator and Pratt & Whitney to collect large amounts of real-time data on engine components based on how it is actually being flown in the field versus an assumed mission mix. This constant flow of data is continuously re-analyzed and allows the customer to take advantage of the full life of the engine parts while reducing risk to the fleet. By capturing full flight data, UBL allows the operator to assess exactly how the aircraft was flown and apply the appropriate level of lifing capacity that was used – saving time and money while improving readiness.

Pratt & Whitney has partnered with the USAF over the last decade to utilize their combined engineering capabilities and logistics expertise to develop advanced tools sets and to capture the streaming data generated in today’s advanced platforms through the full flight of the aircraft/engine. The data is then transferred and processed through the Pratt & Whitney lifing system using advanced algorithms and logistics management tools. Those results are then passed to the maintainer in an actionable format. In order to reach this historic launch, a detailed validation plan was executed with the USAF. Pratt & Whitney captured and authenticated UBL data for two years to validate system functionality and integration points. 

As part of the UBL launch, the entire F-22 fleet stationed at Nellis AFB has been converted to UBL tracking, vastly improving sustainment capabilities; and the F-22 units at Langley AFB are expected to start the conversion in March. In addition to saving money, successfully implementing this technology across the fleet will provide the USAF a model for applying the UBL process to other engine sustainment programs, which will further reduce costs, streamline maintenance, and improve readiness for the nation’s warfighters.

What You Missed:
Inflationary Pressure In Raw Materials & Logistics, Threatens Car Production
Envision AESC And Mercedes-Benz Announces New Battery Partnership
Intel Selects Germany As The Site For A Huge New Chipmaking Complex
AVEVA x Microsoft: Partnership To Optimise Manufacturing Operations
M&H Expands With The Purchase Of Two Additional SLM280 Twin Machines
Carmakers Sharing Data? Your Connected Car Knows You
Component Sourcing: It’s More Than Just Aircraft Parts
Mumbai Is The First South Asian City To Detail Net-Zero Roadmap
Indonesia Miners Looking To Cash In On The Surging Commodity Prices


Letter to the Editor
Do you have an opinion about this story? Do you have some thoughts you’d like to share with our readers? APMEN News would love to hear from you!

Email your letter to the Editorial Team at [email protected]
Airbus Expands MRO Footprint In Asia

Airbus Expands MRO Footprint In Asia

Following separate announcements by Asia Digital Engineering Sdn BhD (ADE) and Korea Aviation Engineering & Maintenance Service Ltd. (KAEMS) for Airbus customers in Asia, Mathew George, Ph.D, Analyst, Aerospace, Defense and Security at GlobalData, a leading data and analytics company, offers his view:

“AirAsia Group’s ADE and KAI’s KAEMS made separate announcements on the expansion of maintenance, repairs and overhaul (MRO), thus marking an increased footprint for Airbus customers to avail MRO services in Asia. With the pandemic still wreaking havoc, airlines and countries had put on hold the programs to purchase new aircraft and make sure that the lives of the present aircraft be extended safely as much as possible. Countries, including India, actively started to explore MRO services and proposed the possible mechanisms and programs to turn themselves into regional MRO hubs.

According to GlobalData, the military aerospace MRO market is expected to grow at a compound annual growth rate (CAGR) of 2.93 percent in the Asia-Pacific (APAC) region between 2020 and 2030 and will be valued at US$17.85bn by 2030.

While ADE obtained the approval for base maintenance (hangar or C-Checks) from Civil Aviation Authority of Malaysia (CAAM), KAEMS was able to sign an MoU with Airbus Defense & Space (ADS) for technical support for C-212 and CN-235 aircraft. ADE’s support extends not just to AirAsia fleet of A320, A321 and A330 aircraft, the approval allows it to undertake MRO services for other airlines as well. ADE was also able to secure approvals from India’s DGCA and Indonesia, raising the bar for ADE and Malaysia to provide MRO services for airlines across Southeast Asia.

Governments have shown their resolve to fund upgrade and replacement programs. However, with lockdowns continuing in countries, and increasing cases like India’s still a possibility in other geographies, airlines and governments will continue to focus on sustainment of existing capability. In addition, with long lead times and unexpected delays still a possibility, a lackadaisical approach to MRO is not something anyone can afford.”


Check these articles out:

Review: The Future Of Additive Manufacturing In Southeast Asia

Frost & Sullivan: Welding Vendors Focusing On New Technologies And Energy Efficiency

A.I. Engineering Pioneer Hyperganic Raises $7.8m Funding For R&D Expansion In Singapore

How Is COVID-19 Impacting The Aircraft MRO Industry In SEA?

Two Industry Veterans to Lead FARO’s Global Hardware, Software R&D Teams


For other exclusive articles, visit


FOLLOW US ON: LinkedIn, Facebook, Twitter



Advancing MRO Solutions With Additive Manufacturing

Advancing MRO Solutions With Additive Manufacturing

ST Engineering and EOS have collaborated to introduce multiple AM solutions for the aerospace sector—from qualified systems and materials to 3D print certified parts that are more durable and more effective in operations.

ST Engineering’s Aerospace sector has been building its portfolio in virtual inventory to enhance customers’ air operation performance, including solutions for commonly damaged aircraft components. Printing on demand helps eliminate waste when platforms are retired, reducing non-moving inventory. In addition, with approved digital files and qualified 3D printers & processes, certified parts can be produced close to aircraft sites, vastly reducing delivery-related carbon emissions and improving cost efficiencies.

Confident that additive manufacturing (AM) is the way forward, the company collaborates with technology partners and like-minded airline customers to develop multiple AM solutions. Here, ST Engineering shares how they successfully broadened and deepened their capabilities for AM solutions. 

Overcoming Challenges

Back in 2018, ST Engineering already had plans to expand their AM capabilities from Filament Layer Manufacturing (FLM) technologies to include Laser Powder Bed (LPB) technologies- covering the two processes of Selective Laser Sintering (SLS) and Direct Metal Laser Solidification (DMLS) – so as to offer a wider range of additive manufacturing solutions to customers. 

Originally, it only had Design Organisation Approval (DOA) and Production Organisation Approval (POA) from the European Union Aviation Safety Agency (EASA) for FLM technology. For the LPB technologies, the plan was to build in-house capabilities in managing and qualifying the systems, materials and processes, which would in turn open more application potential to produce AM aircraft parts. 

As a new adopter of LPB AM technologies, ST Engineering decided to collaborate with EOS, one of the industry’s pioneering leaders specialising in LPB AM systems, to jumpstart their learning curve in understanding the possibilities and limitations of both SLS and DMLS processes.

AM Solution

By the end of 2018, ST Engineering and EOS’ consulting arm, Additive Minds, established an Additive Manufacturing Capability Transfer program. The program comprised customised training and consulting workshops that aimed to build strong fundamentals among attendees in the following topics: parts screening and selection, design for AM, business case analysis, and introduction on critical-to-quality requirements for AM processes.

After the Capability Transfer Program, ST Engineering selected a load-bearing cabin interior assembly with no impact on flight safety from their converted freighter aircraft as a benchmark to kickstart their adoption journey with both SLS and DMLS technologies. 

To continue reading this article, head on over to our Ebook!


Check these articles out:

Simulation Irons Out Metal Binder Jetting Defects To Enable Mass-Production AM

Bombardier Partners With ST Engineering To Build Singapore Service Centre

EOS And Audi Expand Range Of Applications For Metal 3D Printing

Aircraft Milled Parts Market To Reach US$4.3B In 2025

2021 Metals Analysis Outlook: Optimising Production Through Connectivity


For other exclusive articles, visit


FOLLOW US ON: LinkedIn, Facebook, Twitter




Rolls Royce Discovers Cracks In Engine Blades

Rolls Royce Discovers Cracks In Engine Blades

Already dealing with the financial struggles of COVID-19, Rolls Royce has discovered technical problems with its Trent XWB engines. Routine inspection found cracks in its compressor blades on a small number of its XWB engine which powers the Airbus A350 widebody aircraft.

Previously, issues with its turbine blades fitted to its Trent 1000 engines powering the Boeing 787 are costing £2.4 billion to fix over 2017-2023. Adding on to the costs, Rolls Royce could spend an estimate of £50 million to fix the issue with its Trent XWB engines.

None of the Trent XWB engines in service have reported any issues with flight prior to the discovery of the fault, however those with similar service life will also be inspected. The group assures investors and customers that this issue will not cause significant disruptions for carriers or material annual costs.

According to Globaldata, Rolls-Royce has been one of the worst affected aerospace companies and has announced 9000 job cuts. Its wide-body engine flying hours, the lifeline of the company’s commercial business, fell by 75 percent in Q2.

For other exclusive articles, visit


Check these articles out:

Vietnam’s First Aircraft Engine Component Factory Has Began Operations

3D Printed Miniature Jet Engine Works, Uses Compressed Air

Airbus Commits To Continued Automation Of Its Manufacturing Line

NASA Develops New 3D Printing Method For Producing Rocket Engine Nozzles

Airbus, Rolls-Royce And Siemens Partner On Hybrid Electric Aircraft

Frost & Sullivan Names Top Innovators In The Global Commercial Aircraft MRO Market

Rolls-Royce And Intel To Collaborate On Autonomous Shipping Systems



FOLLOW US ON: LinkedIn, Facebook, Twitter


APMEN SURVEY: COVID-19 Impact On Manufacturing Industry

APMEN SURVEY: COVID-19 Impact On Manufacturing Industry

The COVID-19 pandemic has been having an unprecedented impact on the global manufacturing supply chain. For instance, factory shutdowns have drastically impacted the metalworking supply chain around the car and auto parts manufacturing industries.

In line with our continuing coverage of the impact of COVID-19, Asia Pacific Metalworking Equipment News (APMEN) recently conducted a survey regarding the impact of the COVID-19 pandemic to the manufacturing industry, including automotive and auto parts, aerospace and aerospace parts, electronics/electrical equipment, die and mould, machine tool, and medical device/equipment sectors.

Key questions include the challenges they experienced as a result of the pandemic; expected impact on their 2020 sales compared to last year; the most likely impact on their supply chains in the next six months; and whether they are expecting a pent up demand after the pandemic.

Here are some key findings:

  • 71 percent of respondents saw a decrease in demand for their products because of the lockdowns in every market worldwide.
  • Perhaps because of the drop in demand, majority or 47 percent of the respondents expect pent-up demand after the pandemic.
  • 55 percent of manufacturers surveyed, expect a decrease of more than 10 percent in sales this year
  • In line with that, 21 percent are saying they will diversify their supply chains by working with more suppliers, and 16 percent say they will shift to a localized supply chain.

For the full survey results, keep a look out for APMEN’s upcoming Jul/Aug issue!

Staying Connected

During a crisis, a spotlight is placed on the importance of the connection between a brand and its clients. In fact, 40 percent of our respondents say staying connected with their customers are among the key challenges they’ve experienced during the pandemic.

Your clients might be panicking, but it is important to provide them with anchors from your business to act as a focal point, like a beacon of light in a dark time.

It is key to establish such a light source through various human touchpoints. You should remind them of your shared experiences and the results that were delivered—and one way to do so is through targeted branding exercises for your business. Branding opens doors and creates new avenues for clients to reach out to you while seeing the value in doing business with you.

We at Asia Pacific Metalworking Equipment News (APMEN) would be very happy to help you on this front. Reach out to us and find out more about our solutions!

For other exclusive articles, visit


Check these articles out:

Impact of COVID-19 On The Automotive Manufacturing Supply Chain

Developing Asia Growth To Fall In 2020 On COVID-19 Impact

Automotive Manufacturing Developments In Southeast Asia Amid COVID-19

Global Spending on Defence Declines as Governments Allocate Funds to Reactivate the Economy

COVID-19 Impact On Global Machine Tool Market

[WATCH] Siemens Discusses Initiatives, Outlook Amid COVID-19

Renishaw Sees Continued Demand for Accuracy and Precision Driving Growth



FOLLOW US ON: LinkedIn, Facebook, Twitter



[WATCH] APMEN Speaks On The Impact Of COVID-19 On ASEAN’s Metalworking Industries

[WATCH] APMEN Speaks On The Impact Of COVID-19 On ASEAN’s Metalworking Industries

In a webinar hosted by Taipei International Machine Tool Show (TIMTOS), Kenneth Tan, Publisher of Asia Pacific Metalworking Equipment News (APMEN) speaks about the impacts of the pandemic on ASEAN’s metalworking industries, including the automotive, and aerospace & MRO sectors and what we can expect in the post COVID-19 era.

Besides the ASEAN region, the webinar, organised by Taiwan External Trade Development Council (TAITRA), also addresses the impact of COVID-19 in the European and US markets. Other speakers include Gabriel Pankow, Head of Digital Editorial Office of mi connect and Michael Vaughn, Chief Consultant of Indiana Research Institute.

Watch the full webinar here:

For other exclusive articles, visit


Check these articles out:

LVD Launches Virtual Tech Summit For Metal Fabricators

What To Do With Your Coolant During Longer Production Stops?

Metals, Electronic Systems, External Manufacturing Slows Down Due To COVID-19

Taking metal to the cloud

ASEAN Vehicle Sales Down 19% In Q1 2020

Increasing Productivity And Quality Gains Through Digitalisation



FOLLOW US ON: LinkedIn, Facebook, Twitter


ASEAN Aerospace And MRO Industry In The Wake Of COVID-19

ASEAN Aerospace And MRO Industry In The Wake Of COVID-19

The COVID-19 pandemic has an unprecedented adverse impact on the aviation industry and, consequently, on the MRO business, without clear visibility on the timing of its recovery, according to Singapore-based SIA Engineering Co. Ltd. Border controls imposed by countries worldwide and the precipitous decline in travel demand has forced drastic cuts in flight capacities and grounding of aircraft.

In response to the worsening crisis, the International Air Transport Association (IATA) is projecting a more realistic U-shaped recovery for the air travel industry, with domestic travel coming back faster than the international market. 

Many expect that because of the impact of the pandemic, activity in the commercial aerospace market will take several years to return to the levels seen just a few months ago. Some players in the aerospace manufacturing industry, including Boeing and Rolls-Royce, have even announced workforce reduction and production cuts.

However, Boeing is seeing some green shoots. Some customers are reporting that reservations are outpacing cancellations on their flights for the first time since the pandemic started, while some countries and U.S. states are starting cautiously to open their economies again.

  • Boeing, in fact, has resumed production of the 737 MAX at the company’s Renton, Washington factory.
  • On 14 April 2020, IATA released an updated analysis showing that the COVID-19 crisis will see global airline passenger revenues drop by US$314 billion in 2020, a 55 percent decline compared to 2019. Airlines in Asia Pacific will see the largest revenue drop of US$113 billion in 2020 compared to 2019 (-US$88 billion in 24 March estimate), and a 50 percent fall in passenger demand in 2020 compared to 2019 (-37 percent in 24 March estimate).

According to Oliver Wyman:

  • As of late April, over 65 percent of the pre-COVID fleet of 27,500 commercial aircraft have been parked
  • The current trajectory for fleet reductions and lower aircraft utilisation would reduce global MRO demand in 2020 by over $48 billion, or 53 percent

Here’s an update of what has been happening in ASEAN’s aerospace and MRO industry amid the ongoing COVID-19 pandemic.


  • Indonesia’s national airline, Garuda Indonesia, has resumed domestic flights starting May 7, 2020.
  • PT Garuda Maintenance Facilities (GMF) AeroAsia expects to see increasing demand for MRO services from non-affiliated international airlines and has projected an 80 percent y-o-y increase for MRO services, from 71 percent in 2019


  • AirAsia is set to gradually resume services in the Philippines on June 5, 2020, following the Philippine government’s directive of easing community quarantine restrictions in Metro Manila and several parts of the country. The resumption of services will initially be for key domestic routes, and will gradually increase to include international destinations by July 1.
  • Air Carriers Association of the Philippines (ACAP), comprising: Philippine Airlines, Cebu Pacific and AirAsia Philippines, sees the industry shrinking in the next two years. The association has requested government assistance, including waiver of airport charges and credit guarantees
  • Infrastructure projects still ongoing: Lufthansa Technik and Metrojet Engineering


  • Airbus withdraws from MRO joint venture with Thai Airways
  • Thai Airways has filed for bankruptcy protection to rehabilitate business (to restructure under the supervision of the local bankruptcy court). Will not resume its international flight operations until 30 June.
  • The proposed MRO project at the U-Tapao Airport will proceed as planned despite Thai Airways International (THAI) entering bankruptcy. The THB11 billion project has already been approved by the Cabinet and a contract is expected to be signed in June. (The Nation Thailand)


85 percent of the Singapore industry is involved in maintaining and repairing aircraft. Singapore also plays a small but critical role in the global aerospace supply chain, with its SMEs having a key role in MRO and manufacturing—supporting special processes, tooling, testing, logistics, manpower, and other services. (Association of Aerospace Industries Singapore)

  • SIA has announced that it will resume flights to 27 destinations and increase no. flights for other services in June & July
  • Government has set aside S$750 million of support for the aviation sector and consolidation is expected to happen over the next 12 to 18 months.
  • Collins Aerospace, which just opened a 10,000 sq ft innovation hub in Singapore, is “monitoring the evolving market conditions very closely”. 
  • Rolls-Royce has scaled down its operations in its facility which tests Trent aero engines (Channel News Asia)
  • ST Engineering 
    • expects a slowdown in its aerospace unit due to deferred MRO services and lowered original equipment production rates 
    • however, the company has secured about $838 million across its spectrum of aviation manufacturing and MRO businesses
      • The MRO contracts included A320 heavy maintenance contracts and CFM56-7B engine maintenance contracts from Chinese airlines, and a component Maintenance-By-the-Hour (MBHTM) contract from a Southeast Asian airline to provide comprehensive component maintenance services for its entire fleet of Boeing 737 and Bombardier Q400. 
    • The Group is discussing with its customers to adjust delivery schedules or address order cancellations due to the evolving crisis. As at the end of 1Q, the Group’s order book remains robust.
  • BOC Aviation, a company involved in aircraft sales and leasing has extended its Engine MRO contract with Lufthansa Technik for another five years.
  • Through the enhanced Jobs Support Scheme (JSS), companies such as ST Engineering and SIA Engineering Company (SIAEC) will receive millions in additional wage support to cushion the devastating blow that COVID-19 has dealt the aerospace industry. (The Business Times)


  • Suspended all international and most domestic flights in March and April in an effort to curb the spread of the coronavirus, domestic flights have resumed since April 22, after the government lifted a lockdown order, while international flights are expected to partially resume from June 1.
  • Will not consider applications for new airlines as it looks to prioritise the recovery of its aviation sector after the impact of the novel coronavirus, according to the Civil Aviation Authority of Vietnam (CAAV). (Bangkok Post)


For other exclusive news and information, visit


Check these articles out:

Share Your Insights: COVID-19 & Your Business

Developing Asia Growth To Fall In 2020 On COVID-19 Impact

COVID-19 Updates: Auto Makers Revving Up Production To Drive Market Recovery

ST Engineering Drops Dormant Subsidiary From Aerospace Arm

Siemens Workplace Distancing Solution Helps Manage ‘Next Normal’ Manufacturing

GE Aviation And SIAEC Establish Joint Venture

Growth Of Malaysia’s Aerospace Industry

ST Engineering’s Cybersecurity Solutions Gains Global Recognition

Global Aerospace 3D Printing Market Poised To Surpass $2,857 Million By 2024



FOLLOW US ON: LinkedIn, Facebook, Twitter




Back To Top