NASA has successfully tested the most complex rocket engine parts ever designed by the agency and printed with additive manufacturing, or 3-D printing, on a test stand at NASA’s Marshall Space Flight Center in Huntsville, Alabama.
NASA engineers pushed the limits of technology by designing a rocket engine injector –a highly complex part that sends propellant into the engine — with design features that took advantage of 3-D printing. To make the parts, the design was entered into the 3-D printer’s computer. The printer then built each part by layering metal powder and fusing it together with a laser, a process known as selective laser melting.
The additive manufacturing process allowed rocket designers to create an injector with 40 individual spray elements, all printed as a single component rather than manufactured individually. The part was similar in size to injectors that power small rocket engines and similar in design to injectors for large engines, such as the RS-25 engine that will power NASA’s Space Launch System (SLS) rocket, the heavy-lift, exploration class rocket under development to take humans beyond Earth orbit and to Mars.
3-D Printed Rocket Injector Roars to Life: The most complex 3-D printed rocket injector ever built by NASA roars to life on the test stand at NASA’s Marshall Space Flight Center in Huntsville, Alabama.
“We wanted to go a step beyond just testing an injector and demonstrate how 3-D printing could revolutionize rocket designs for increased system performance,” said Chris Singer, director of Marshall’s Engineering Directorate. “The parts performed exceptionally well during the tests.”
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