3DPOD 316: Beehive’s Gordie Follin on 3D Printed Engines and More

Key Takeaways

• Gordie Follin brings 30 + years of aerospace engineering experience from Pratt & Whitney, GE, and GE Aviation to Beehive Industries.
• He led GE’s Catalyst engine program, the first commercial turbofan to use additive manufacturing for > 70 % of its parts.
• Beehive is scaling a family of low‑cost 3‑D‑printed jet engines by ordering Nikon SLM Solutions and EOS metal‑printer fleets and by acquiring precision‑machining shops.
• The company’s current capital spend exceeds US$250 M on printers, tooling, and plant automation.
• Comparative data show Nikon’s 12‑laser SLM platform offers larger build volume, while EOS focuses on higher laser power for dense alloys—both critical for jet‑engine production.

Who Is Gordie Follin?

A Veteran of the Aerospace Power‑train World

Gordie Follin spent two decades designing high‑pressure turbine components at Pratt & Whitney, followed by senior engineering roles at GE and GE Aviation. His most visible achievement was serving as Executive Director of GE’s Catalyst engine program, a 2020‑launch turbofan that used additive manufacturing for more than 70 % of its structural metal parts (including fuel nozzles, combustor brackets, and low‑pressure turbine blades).

From Program Leader to Chief Product Officer

In 2023, Follin joined Beehive Industries as Chief Product Officer (CPO). His mandate: turn the concept of “affordable, 3‑D‑printed jet propulsion” into a production‑ready product line.

Beehive’s Scaling Playbook

1. Massive Printer Procurement

• Why it matters: The Nikon SLM‑X12’s larger envelope enables single‑piece engine housings up to 350 mm in diameter, cutting assembly steps. EOS’s higher laser power accelerates the sintering of dense superalloys, reducing cycle time from 12 h to 7 h per batch.

2. Vertical Integration Through Acquisitions

Beehive has bought three mid‑size CNC‑turning firms (combined capacity of ≈ 2 000 hrs/month) to finish printed cores, drill oil passages, and apply protective coatings. This reduces lead‑time from 12 weeks (outsourced) to 5 weeks for a complete engine.

3. Targeted Capital Expenditure

• Total 2024 spend: US$250 M (≈ US$150 M on printers, US$70 M on machining assets, US$30 M on automation software).
• Projected output: ≈ 500 engines/year by 2026, each priced under US$150 k, versus the typical US$1‑2 M for conventional turbofans of similar thrust.

4. Smart Production Controls

Beehive implements a digital twin for each engine model, linking printer telemetry, melt‑pool monitoring, and post‑process inspection data. Early trials show a 30 % reduction in defect‑related re‑work.

The Opportunity Landscape

• Regulatory headroom: The FAA’s 2022 “Additive Manufacturing for Propulsion” guidance opens a pathway for Class 2 engines under 10 kN thrust to be certified with reduced flight‑test hours.
• Market demand: Regional airlines and unmanned‑air‑system (UAS) manufacturers seek sub‑US$200 k propulsion solutions that can be produced locally, cutting supply‑chain risk.
• Competitive edge: By merging large‑format SLM with in‑house CNC finishing, Beehive can deliver integrated engine assemblies in a single supply chain—something most legacy OEMs cannot match today.

Bottom Line

Gordie Follin’s aerospace pedigree and his stewardship of GE’s Catalyst program give Beehive Industries a rare blend of technical credibility and production know‑how. The company’s aggressive acquisition of high‑capacity Nikon and EOS metal printers, combined with strategic machining buyouts, positions it to industrialize low‑cost, 3‑D‑printed jet engines at a scale few competitors can achieve. With a projected output of 500 units per year and pricing under US$150 k, Beehive is poised to reshape the propulsion market for regional aviation and high‑performance UAVs, delivering a compelling value proposition backed by measurable engineering data.