HLH Prototypes specializes in 3D Printing Prototype Services. Regardless of your field, our expertise in additive manufacturing technologies is ready to bolster your product development efforts. For those uncertain about the advantages of 3D printing for their projects, NASA’s experience with a 3D-printed Rocket Engine Nozzle offers compelling insights.
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NASA utilized additive manufacturing to create a lighter yet critical component—a development that’s poised to significantly impact deep space exploration, particularly for missions requiring additional payloads. This 3D-printed rocket engine nozzle is notably lighter than its traditional counterparts, yet it doesn’t sacrifice strength.
Introducing a new aluminum blend
In developing this innovative part, NASA collaborated with Elementum 3D to engineer a special aluminum that is both weldable and highly resistant to heat, making it ideal for rocket engine applications. While aluminum is celebrated for its superior strength-to-weight ratio and lower density compared to other metals, its susceptibility to heat and tendency to crack during welding has limited its use in 3D printing rocket engine prototypes.
Through the RAMFIRE (Reactive Additive Manufacturing for the Fourth Industrial Revolution) project, NASA has been able to progress in the development of lightweight, 3D-printed aluminum rocket nozzles. These nozzles feature intricately designed internal channels that help maintain cool temperatures, reducing the risk of melting under extreme heat.
Accelerating production
Traditional nozzle manufacturing can involve assembling thousands of individual parts. In contrast, the RAMFIRE project’s nozzle is designed as a single piece, drastically reducing the need for multiple welds and, as a result, shortening production times.
The aluminum variant used (A6061-RAM2) is specifically formulated for 3D printing the nozzle prototype, enhanced further by LP-DED (laser powder directed energy deposition) technology. RPM Innovations leveraged this novel aluminum and specialized powder to fabricate RAMFIRE nozzles using LP-DED.
Seeking lightweight and durable parts?
Explore our 3D printing prototype services. With advanced methods like DMLS (Direct Metal Laser Sintering), we’re equipped to deliver lightweight, premium-quality metal components for your next project. Start a complimentary project review to find out more.
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