Humanity never stops reaching for the stars. And the use of 3D printing is making it more common than ever! Building upon previous projects using additive manufacturing for rocket engines, we have yet another case study: Italian company AVIO SpA has successfully completed tests of its MPGE (multi-purpose green engine). SLM 3D printing was used in its creation.
The project was made as part of the Italian’s government PNRR program, which is part of a movement to strength the growth potential of the country. More specifically, it falls under the purview of the “Satellite Technologies and Space Economy” theme as part of a sub-investment into in-orbit economy as Italy seeks to increase its role in the Space Race. In particular, it seems that the MPGE is part of efforts to increase Italy’s capacities in the field of space logistics for the surveillance of the space environment (Space Situational Awareness) and the management of space traffic (Space Traffic Management).
A conceptual image of the MPGE rocket engine (photo credits: AVIO SpA)
AVIO was entrusted the MPGE project, part of an Italian Space Agency contract, and worked on it in collaboration with Sòphia High Tech. The bi-propellant rocket completed its first ignition tests on February 24, 2025. But how was it made?
Using 3D Printing and Traditional Manufacturing to Make the MPGE
As mentioned, the successful test of the MPGE engine is a huge move forward for the Italian space industry. And it is particularly interesting to use because the goal of the MPGE engine is to be ‘greener’ than many rocket engines. How? By using both hydrogen peroxide and kerosene as fuel. And additive manufacturing had quite the role to play.
According to information from Sòphia High Tech, which was charged with creating the combustion chamber, thermal control system, nozzle extension and injection section, both 3D printing and CNC machining were used to make the MPGE. More specifically, Sòphia High Tech notes that its team using Selective Laser Melting, which has been qualified and is able to comply with the advanced standards prescribed by the ECSS-Q-ST-70-80C standards of the ESA, and a nickel-based material. Although the 3D printed used is not explicitly mentioned, the Aerospace company often uses a TruPrint 3000 from Trumpf and it is likely that that was what was used in this case as well.
In addition to additive manufacturing, each mechanical part required several phases of dimensional control and validation at different stages. For example, heat treatment, depowdering and mechanical finishing using CMC machining were all necessary steps. Sòphia Tech created its own production cycles to ensure full compliance with tight mechanical tolerance, both geometric and dimensional, in the parts.
In any case, the successful testing of the MPGE project clearly shows the advantages of combining additive and traditional manufacturing to create rocket parts. It also shows the strength of Italy’s manufacturing sector, as the entire environmentally friendly engine was made in the country. Ultimately, the MPGE project seeks to qualify an innovation propulsion system for use in both launch systems and orbital and suborbital space applications.
Image Credits: 3Dnatives
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*Cover Photo Credits: AVIO SpA