Editor’s Note
This article highlights a significant milestone in India’s aerospace sector, where startup DG Propulsion has developed a 3D-printed core engine module as a single integrated part—a notable shift from traditional multi-component assembly. This innovation could streamline production and enhance efficiency in jet engine manufacturing.
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India is now moving towards a new revolution in jet engine manufacturing. Indian aerospace startup DG Propulsion has achieved a remarkable feat that could completely transform the country’s engine production. The company recently developed a new 3D printed core engine module, which is entirely different from all previous designs. The key feature is that while previously 9 separate parts had to be assembled for this engine, it has now been manufactured as a single integrated part.
DG Propulsion founder Prateek Dhawan shared information about this achievement on social media on October 21. He explained that this new engine module is fully built using metal 3D printing technology, which has reduced production time by up to 40%. Not only that, it has also made the engine 15-20% lighter and achieved a cost saving of 30-50%.
This engine module functions as the core part (compressor or diffuser section) of small jet engines like turbojets or turbofans. Previously, manufacturing these required joining several parts, with welding between them. This welding would become a cause of thermal fatigue over time. However, DG Propulsion’s new design is weld-free, making it stronger and more durable.
This module has been 3D printed using strong metals like Inconel 718 or titanium. It also incorporates internal heat-dissipation lattice structures and cooling channels, allowing the engine to perform better without overheating. The company claims that this new design will not only double the engine’s lifespan but can also be fitted into Indian UAVs and missiles like CATS Warrior or Nirbhay.
DG Propulsion received funding in 2024 under DRDO’s Innovations for Defence Excellence (iDEX) program. The company’s target is to develop indigenous turbojet engines within India itself, which can power drones and cruise missiles.