Researchers at the Fraunhofer Institute for Casting, Composite and Processing Technology (Fraunhofer) have reportedly developed a novel 3D-printing process for critical rocket components. This new process is able to use multiple metals at once, enabling parts to be printed in a single run, rather than as separate pieces.
Part of the European Union’s €38 million “Enlighten” project, this innovation should translate to fewer individual components needing to be fabricated. It could, it is claimed, help slash the costs and development time for space programs such as the European Space Agency (ESA).
It should also open the door to the development of more compact, lighter engines with improved performance. Ultimately, this could help Europe build rockets faster and more independently (e.g., Ariane 6 and beyond).
“With this manufacturing process, we can customize components directly on the computer and print them immediately,” Constantin Jugert, a scientist at the Fraunhofer IGCV, explained.
“The enormous flexibility saves us lead times and allows for rapid iterations when requirements change. This saves weeks in development,” he added.
3D printing rocket parts
This is a big deal, as, at present, rocket engines are incredibly complex pieces of engineering. They typically required many machined parts made from various metals.
These parts are then welded or bonded together, with each part subject to exhaustive testing. This is an expensive and time-consuming process, with many potential points of failure.
