December, 2009 (01:44)
The Boeing 787 was designed to be the most fuel efficient airliner. It begins its maiden flight at Paine Field in Seattle, WA.
Rolls-Royce, a Way of Life (03:05)
Rolls-Royce employees 11,000 people for jet engine production. The main assembly plant has been in Derby for 100 years. Rolls-Royce is a part of work and play.
Trent Engines (02:55)
The Trent 1000 is Rolls-Royce's star engine but the Trent 700 is the biggest seller; the company produces four a week. General Electric is Rolls-Royce biggest competitor.
Integrated Logistics Center (02:18)
Each Trent engine is built from eight modules; each module has thousands of components. Logistics Manager Kevin Carr manages the dispatch of parts for every engine build.
Raw materials arrive at the Rolls-Royce factory every day. Workers will transform titanium sheets into Trent engine fan blades. Technical Manager Mike Wallis discusses blade design and function.
Trent Engine Fan Blades (02:56)
Blades are made from three sheets of titanium bonded together in a secret process and inflated with inert gas. Approximately 150 blades are made every week.
Global Company (00:38)
Rolls-Royce sources parts from outside the UK. Cath Taylor sources engine modules from mainland Europe.
96 Turbine Blades (02:14)
Learn how jet engines function. Chief Design Engineer Andy Mylrea discusses the harsh environment the blades must function in.
Rolls-Royce Materials Research Laboratory (01:19)
The laboratory creates metals with the exact physical and chemical qualities demanded by turbine blade designers.
Turbine Blade Facility (04:04)
Workers at the Rolls-Royce facility in Darby grow a single metal crystal into the correct shape. The blade undergoes precision finishing and fitting.
Rolls-Royce, 1971 (04:02)
The small company risked everything on creating the first three shaft engine, the RB211, for the Lockheed TriStar. The engine helped Rolls-Royce become a global competitor.
Production and Test Facility (03:52)
Each Trent engine is assembled in 20 days. Workers assemble an aluminum wrapped fan case, module fitters begin fitting the engine's eight modules together, and Ady Kay assembles the engine fan.
Final Assembly and Testing (01:53)
Workers turn the Trent engine stack on its side and fit the last two modules. After two weeks of assembly, every engine is fitted with aerodynamic ducts and tested.
Rolls-Royce Test Center (02:50)
Chief Development Engineer Dave Benbow manages the testing of new engine design prototypes. See cold, water, and fan case tests.
21st Century Jet Engine Production (03:41)
Fitter Andy Taylor fits the first of a network of sensors to a Trent engine. Data collected in the air is transmitted to the Operations Center and immediately analyzed.
Derby Assembly Line (01:28)
The final module to complete the Trent engine stack is delayed and the assembly line. Workers look for items that can be fitted ahead of schedule while another module is located.
Sixteen-year-old Neeraj Sunger is a manufacturing apprentice in Derby; his family has a history with Rolls-Royce. Sunger attempts to make a control rod.
Customer Delivery Center (02:30)
Engine inspector Mike Riley scrutinizes every Trent engine; his is one of the most specialized jobs on the Rolls-Royce assembly line. An engine leaves the factory to be fitted to an Airbus 330 in France.
December, 2009: Test Flight (02:19)
The Boeing 787 Dreamliner undergoes its maiden flight in Seattle, WA. The team of engineers in Derby watch the flight live online. An order for five 787s is placed.
Credits: How to Build A Jumbo Jet Engine: Voyages of Construction (00:35)
Credits: How to Build A Jumbo Jet Engine: Voyages of Construction
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