A*STAR, Rolls-Royce, and SAESL deepen strategic partnership for aerospace manufacturing and MRO technologies

This press release was jointly issued by Agency for Science, Technology and Research (A*STAR), Rolls-Royce Holdings plc and Singapore Aero Engine Services Private Limited (SAESL).

Singapore’s position as a global aerospace Maintenance, Repair and Overhaul (MRO) and manufacturing hub has been further strengthened with the launch of phase two of the Smart Manufacturing Joint Lab (SMJL). The collaboration between the Agency for Science, Technology and Research (A*STAR), Rolls-Royce, and Singapore Aero Engine Services Private Limited (SAESL) builds on more than two decades of successful partnership and the achievements of SMJL’s first phase.

Launched in 2017, the S$68 million phase one of SMJL explored opportunities for improving process efficiencies and implementing advanced manufacturing technologies in Rolls-Royce’s fan blade production facility and SAESL’s MRO operations, responding to rising global demand in aviation and the MRO market.

The second phase of SMJL will strengthen Rolls-Royce’s manufacturing and SAESL’s MRO capabilities to meet growing global demand. Leveraging new innovations from this phase, together with ongoing improvement initiatives across Rolls-Royce, Fan Blade Singapore (FBSG) will be able to expand fan blade production by more than 30 per cent over the next few years without increasing its facility footprint.

The innovation from the second phase of the SMJL will complement SAESL’s existing S$242 million investment to build new capabilities and double its output, which will reinforce its position as the world’s largest Rolls-Royce Trent Engine MRO facility. SAESL’s expansion alone is expected to create 500 high-value jobs in Singapore over the next five years.

Since its launch, SMJL created local impact, and helped transformed operations for both Rolls- Royce and SAESL:

• 18 transformative technologies deployed across facilities, enhancing productivity, strengthening safety standards, and laying the groundwork for continued growth in the aerospace industry 
• More than 20 per cent increase in productivity recorded in 2024 (over 2017) at Rolls- Royce’s fan blade facility through a mix of SMJL technology adoption and internal initiatives 
• Significant improvement in productivity to enable a 40 per cent increase in SAESL’s output by 2028 
• Over 200 local SMEs engaged 
• Generated over S$4.5 million in immediate business opportunities 
• A total of eight local SMEs added to Rolls-Royce and SAESL’s approved vendor list, after meeting rigorous quality and safety standards, through co-innovation 
• 14 high-value jobs created in Singapore

Phase two of SMJL will focus on three key areas: (i) Advanced technologies for aftermarket services including additive manufacturing processes for component repair and engine overhaul; (ii) Advanced fan blade manufacturing to optimise fan blade production and inspection techniques; and (iii) Advanced manufacturing processes including additive manufacturing and process improvements to enhance component reliability.

Beyond technology advancement, phase two also aims to upskill local small and medium-sized enterprises (SMEs) in advanced manufacturing technologies, expanding business opportunities for the local ecosystem and strengthening Singapore’s value proposition in global aerospace supply chains.

Rolls-Royce and SAESL’s strategic growth in Singapore

Rolls-Royce’s collaboration with A*STAR began in 2002 with an engine modelling research project with the A*STAR Institute of High Performance Computing (A*STAR IHPC). This led to the establishment of the Rolls-Royce Advanced Technology Centre in Singapore in 2004, followed by the launch of a joint Surface Finishing Lab with A*STAR in 2009 to advance manufacturing technologies for the company.

Over the years, the partnership has grown into a robust framework for innovation, capability- building, and industrial scaling. Rolls-Royce contributes product design expertise, global aerospace know-how, and market access, while A*STAR provides deep scientific capabilities in materials, precision engineering, digital manufacturing, infrastructure, and talent development.

In 2020, Rolls-Royce consolidated its global manufacturing of wide chord fan blades into its Fan Blade Singapore (FBSG) facility at Seletar Aerospace Park. Previously split across two global sites, all production for Trent engines – which power around half of the world’s wide-body aircraft – is now centralised at the FBSG.

Established in 1999 and operational since 2001, SAESL has evolved from a modest team of 200 employees in a single building to a workforce of over 2,000 across six buildings spanning three sites—Calshot, Loyang, and Seletar. Today, it stands as the world’s largest MRO facility for Rolls- Royce’s latest-generation Trent engines.

To accelerate growth and reinforce its leadership position, SAESL is undertaking a S$242 million expansion. This includes a new 26,000-square-metre facility that broke ground in early 2025 and repurposing a 25,000-square-meter facility in Seletar. Once completed, it will double SAESL’s overhaul and repair capacity enabling SAESL to service at least 400 engines per year by 2028.

This expansion is part of a broader transformation to ensure sustainable growth over the next two decades. At the heart of this journey is a commitment to reimagining how we work and empowering our workforce—driven by technology adoption. By leveraging advanced capabilities and investing in talent, SAESL is positioning itself to lead the next chapter of aerospace MRO excellence.