The Rolls-Royce company has completed the construction of the first prototype of the UltraFan ultra-large engine, which is expected to be featured on passenger aircraft in the 2030s.
Rolls-Royce continues to develop the UltraFan next-generation engine. This massive green-bladed turbofan engine is the first in a series of engines designed for narrow and wide-body aircraft, delivering thrust ranging from 111,205 to 489,304 Newtons. The fan, with a diameter of 3.56 meters, is nearly 5% larger than the fan on the General Electric GE9X, which is currently the largest engine in the passenger aircraft category.
The UltraFan engine features a 3.56m diameter fan. (Image: Rolls-Royce)
The UltraFan utilizes a new 3D composite manufacturing process controlled by robots, allowing for the creation of complex shapes necessary for aerodynamic efficiency. Engineers opted for titanium for the fan blade edges while the rest is made from carbon composite. This construction is significantly lighter than fans made entirely from titanium found in Rolls-Royce’s Trent engine series. The ultra-light fan is a primary reason Rolls-Royce can manufacture such a large engine while freeing up weight to increase passenger and cargo capacity.
The UltraFan is also equipped with a planetary gearbox between the fan and the rear compressor, enabling the fan to operate at an optimal slower speed while the compressor runs at a higher optimal speed. In initial testing, the gearbox was capable of handling 65 megawatts (87,000 horsepower).
While the UltraFan’s fan has a massive diameter, the turbine inside is relatively compact. Rolls-Royce engineers ensured that the large volume of air flows around the core of the compressor and directly out the back of the engine, rather than being routed through the engine core to drive the compressor. This design results in a high bypass ratio, which helps reduce noise by 35% and significantly enhances fuel efficiency.
Rolls-Royce stated that the UltraFan will use approximately 25% less fuel compared to the first-generation Trent engines, leading to lower operating costs, longer range, and being more environmentally friendly. The engine model also effectively captures NOx emissions, reducing emissions by 40% while generating fewer fine particulates. The UltraFan is designed to operate on 100% sustainable aviation fuel. Rolls-Royce is also exploring hybrid hydrogen-electric engines to completely eliminate carbon emissions.
After completing the assembly of the engine, the Rolls-Royce team will begin testing the UltraFan at the new $108 million Testbed 80 facility in Derby, England, the largest and smartest testing facility in the world.
