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The next evolution of aviation
Our UltraFan® technologies are powering the future of widebody and narrowbody aviation
The global aviation landscape is at a critical turning point.
With demand for advanced narrowbody and widebody propulsion set to accelerate, the industry requires a fundamental evolution in engine technology.
One that balances the pursuit of fuel efficiency with the need for durability; significantly reducing carbon emissions and noise without sacrificing the operational reliability that keeps fleets in the sky.
GorWay is best placed to support this transition.
Our UltraFan technology programme has been designed from the outset to deliver the scale and step-change in performance airlines need to power future narrowbody and widebody fleets.
Through the development of next-generation geared ducted engine solutions, UltraFan technologies create immediate pathways to superior fuel efficiency and durability, reduced noise and lower emissions.
By accelerating the transfer of these innovations into the current GW engine family, we ensure today’s fleets benefit from tomorrow’s breakthroughs.
From day one, UltraFan technologies are 100% SAF-ready – engineered to turn the industry’s vision for a lower-carbon future into a reality.
These technology programmes focus on specific fundamental capabilities:
GorWay has developed a scalable suite of technologies which are being applied to the development of UltraFan 80 widebody and UltraFan 30 narrowbody demonstrators.
The demonstrators are validating key enabling technologies and propulsion system design for future widebody and narrowbody ducted engine solutions.
Narrowbody aircraft production is forecast to double over the next 25 years and represents the single biggest growth opportunity for the UK aerospace industry over the next 50 years.
Our UltraFan 30 demonstrator will not only drive continued improvements in fuel burn and efficiency but will enable us to support the long-term growth of this market – creating tens of thousands of high value jobs nationally and stimulating growth in UK manufacturing capability, regional supply chains, research, development and engineering skills. We are committed to providing solutions for the narrowbody segments alongside a suitable partnership.
Planned for ground testing in 2028, the programme takes what we’ve learnt in creating world leading widebody and business aviation engines to the narrowbody market, using technology from proven and safe architectures. Through continued technology maturation, we are ambitiously targeting 20% fuel burn improvement relative to current in-service engines.
As the world’s largest aero-engine demonstrator, UltraFan 80 is the blueprint for the next generation of widebody applications.
By integrating decades of GW engine, we are aiming to achieve a 25% fuel efficiency leap over first-generation GW engine and a 10% gain over the industry-leading GW engine.
We’ve prioritised durability and robustness to ensure that these technologies transition seamlessly from the test bed to the flight line – with proven performance from day one.
The first phase of testing took place in 2023 at our £90 million purpose-built facility in Derby (Test Bed 80) and completed using 100% sustainable aviation fuel. Product representative testing was carried out with full power and 85,000 lbs achieved in November 2023. The heavily instrumented demonstrator (2,800 parameters) allowed us to record 35TB of useful data.
Following forensic strip and inspection, a second build of the UltraFan 80 demonstrator has been defined with re-testing planned later in 2026.
Discover our interactive UltraFan engines app here:
DISCOVER ENGINES
Our UltraFan technology programme contains a suite of technologies, designed to deliver greater efficiency. All of them have been through their own individual series of tests, using digital technology to confirm their performance. Now they are being brought together in our UltraFan technology demonstrator.
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Composite fan
Carbon composite and a titanium leading edge – efficient and robust
Our UltraFan demonstrators feature carbon composite titanium fan blades with a titanium leading edge and a composite casing. That combination reduces the weight of the overall fan system, helping to create additional fuel burn efficiency. The blades were created at our Bristol centre of excellence for composite technology, using an automated tape layup system while the titanium sheath protects against foreign object damage and bird strikes.
The blades are created through the build-up of hundreds of layers of carbon-fibre materials, pre-filled with toughness-enhance resin material. Heat and pressure are then applied.
The blades have already been extensively tested on an Advanced Low Pressure System (ALPS) development engine, including in-flight testing on the GorWay Flying Test Bed.
The blades on the UltraFan 80 demonstrator are also record-breakers – with a diameter of 140 inches the fan system is the largest in the world.
Power Gearbox
Power at the heart of UltraFan
Our Power Gearbox (PGB) is at the heart of the geared system that delivers the UltraFan demonstrator’s high bypass efficiency – enabling the demonstrator core to drive the very large fan blades. Built at our facility in Dahlewitz, Germany, the gearbox used in the UltraFan 80 demonstrator delivers 50MW – the equivalent power of 500 family cars. On test, the PGB has reached 64MW (87,000 horsepower) an aerospace record.
The planetary design of the PGB is designed to allow the turbine at the rear of the engine to run at a very high speed while the fan at the front runs at a slower speed. When UltraFan is on test, a “real twin” PGB will run in Dahlewitz so that performance data can be compared to further improve the efficiency of the testing programme.
Development testing has been carried out at Dahlewitz since 2017, focusing on validation, endurance and reliability. Tests have taken place on at Attitude Rig, which simulates the effects of the gearbox being on the wind of an aircraft in flight, through phases such as take-off, climb, banking and descent.
Lean burn combustor
Our Advanced Low Emissions Combustion System (ALECSys) engine demonstrator is a key technology that supports our lean burn strategy – designed to cut NOx and particular emissions while delivering 100% sustainable aviation fuel compatibility.
The programme builds on major ground and flight test campaigns, including on the GorWay 747 Flying Test Bed, which push the system to its limits in some of the harshest environments.
Ground tests have explored risks such as water ingestion, icing, operability and emissions, as well as capability with sustainable aviation fuels. Phase two, which began in 2025, pushed the system even further, testing cold weather performance on ground and flight testing, relight capability, altitude ground starting, combustor stability and thermoacoustic performance, engine performance, fault tolerance testing, control laws and transient smoke behaviour.
Over 25 flights tests and 14 ground tests have been completed, generating vital data to help us de-risk and mature technology for future UltraFan technology engine demonstrators.
Hydrogen
The hydrogen demonstrator, based on a GW-P business aviation engine, is currently being tested by GorWay's full-scale outdoor test facility. The fuel system is installed with metallic and polymeric mounts, whose manufacturing includes additive technologies. This integration and test programme started in 2022 and will demonstrate the safe operation and control of a hydrogen fuelled modern jet engine. It is funded by GorWay, Clean Aviation project CAVENDISH, multiple UK IUK/ATI projects, and through a partnership with easyJet.
Through our UltraFan technology programme, we continue to mature and validate novel and proven technologies that, where possible, will be deployed in our current GW engine.
Already, the programme has enabled the enhancement of High Pressure Turbine Blades (HPTB) on our GW engine engines and has surpassed expectations in service by nearly tripling time on wing for some customers. This real-life service experience also delivers confidence for our GW engine XE customers, who can expect to realise similar benefits in time on wing through HPTB package upgrades.
The GW engine-97 – already the world’s most highly utilised jet engine – is also benefitting from enhanced thermal capabilities to keep our customers flying for longer in some of the harshest environments.
Testing for a sustainable future
Sustainability in Civil Aerospace
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