Application of the Month: 3D-Printed Rocket Nozzles Made Using DED
Additive manufacturing has profoundly changed the design, testing and production process for parts used in the aerospace sector. This industry benefits not only from reduced production times, but also from improved characteristics of the parts manufactured. In this context, SAB Aerospace has developed the first demonstration model of one of its rocket nozzles, using Prima Additive’s DED (directed energy deposition) technology.
In keeping with Prima Additive’s philosophy, “Crafting the Future of Space One Layer at a Time,” this nozzle design represents a breakthrough for the conduct of space missions. Indeed, the rocket nozzle is an essential part of the engine. It is mainly used to channel the hot gases generated during fuel combustion. The integration of DED technology brings an improvement to nozzle manufacturing. This process, which used to be complex and often time-consuming, is now more efficient thanks to this method. But why choose this technology?
SAB Aerospace Relies on Inconel® and 3D Printing for Rocket Nozzles
SAB Aerospace has adopted DED technology to simplify the manufacturing of large metal parts. Unlike processes such as SLS or FDM, which require a closed chamber and are limited by its dimensions, DED enables large parts to be produced without being restricted by the size of the machine.
To manufacture the nozzle, SAB Aerospace uses Prima Additive’s Laserdyne 795XL metal printer, equipped with DED technology. With a manufacturing volume exceeding one cubic meter, this machine produces large, highly complex parts, combining speed, precision and efficiency. Usually, a rocket nozzle requires the assembly of thousands of parts. But thanks to 3D printing, SAB Aerospace can now manufacture this nozzle in a single piece, simplifying the design and significantly reducing production times.
The rocket nozzle is also made of Inconel®, a material renowned for its strength. This nickel-based material, alloyed with chromium and iron, is a registered trademark of Special Metals Corporation. It enables us to produce a nozzle that is lighter and more efficient than conventional models. This is important for long-distance space missions, where weight is an essential factor. Indeed, in the field of space exploration, lightening every component is important.
Inconel® material
Inconel® is also appreciated in the aerospace sector for its resistance to corrosion and its ability to withstand variations in temperature and pressure, properties which are essential for its use in space. Thanks to its thermal properties, Inconel® can withstand temperatures up to 40% higher than those borne by conventional alloys.
Indeed, it excels in high-temperature environments, notably between 500° to 600°F (260° and 316°C), and can withstand even higher temperatures, ranging from 1200° to 1400°F (649° to 760°C). By choosing 3D printing as a technology and adopting these latest-generation materials, initiatives like SAB Aerospace’s are paving the way for new advances. The SAB Aerospace nozzle also incorporates internal micro-channels directly into its structure, providing thermal regulation to avoid the risk of overheating in extreme propulsion conditions.
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*All Photo Credits: SAB Aerospace
