Project

3D Printing for Low-Cost Space Components

Maximum safety, high performance and a long service life –

are important requirements that space propulsion systems must meet. Current propulsion technologies already succeed here, but how do they perform regarding cost-effectiveness and reusability?

3D Printing for Low-Cost Space Components (3D-LoCoS)

 

Duration

01.01.2019 – 31.12.2021

Field of application

  • Reusability of launch systems
  • Transition from expensive one-off production to cost-efficient mass production of satellite constellations
  • Use of disruptive technologies such as additive manufacturing

Budget

2.7 million euros

Scientists at the German Aerospace Center (DLR) are focusing on these parameters in the "3D-LoCoS – 3D Printing for Low-Cost Space Components" project. The focus is on the further development and application of metal additive manufacturing, i.e. 3D printing processes. This enables technology demonstrators for space components to be produced more cost-effectively and more quickly.

New production process on the test bench P8

Hot run tests at the P8 research and technology test bench in Lampoldshausen have shown that both the design and the manufacturing process of the 3D-printed combustion chamber with a thrust of 25 kilonewtons were successful. "With six hot run tests, we were able to demonstrate the great potential of the new design and functionality of the 3D-printed combustion chamber," says Dmitry Suslov. "Now we want to quickly bring this technology into industrial application. The test series has proven that additive manufacturing offers a wide scope for the design and construction of engine components." Innovative design methods based on Artificial Intelligence (AI) have also been used throughout the project – from the design of the combustion chamber to testing on the test bench.

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Video: Test of the 3D-printed combustion chamber with the fuel combination of liquid oxygen and methane
The combustion chamber is initially precooled by the methane flowing through it. This causes moisture in the air to condense and ice to form on the combustion chamber. Cooling begins in the nozzle neck and continues upstream to the injection head. When the combustion chamber is ignited, heat is transferred to the cooling medium and the ice melts and evaporates.
Image: 1/2, Credit:
Insight into the development process of the 3D-printed combustion chamber
Before the 3D-printed combustion chamber can be manufactured in one piece by an industrial company, smaller versions (pictured here) up to 30 centimetres in size are developed and tested in DLR laboratory printers. It took two and a half weeks to produce the final combustion chamber in one piece.
Image: 2/2, Credit:

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DLR institutes & facilities involved

Institute for Materials Research

The Institute for Materials Research focuses on the development of new material solutions and their process technologies for applications in the aerospace, energy and automotive sectors.

Institute of Structures and Design

High-performance lightweight structures for aerospace, vehicle construction and energy technology are the focus of research at the Institute of Structures and Design.

Institute for Software Technology

The Institute of Software Technology researches new software technologies and uses them to develop sophisticated software solutions for DLR applications.

Research and Test Infrastructure

Research and Test Infrastructure

Research and Technology Test Bench P8

The P8 research and technology test bench enables the testing and development of individual engine components through to entire propulsion systems with a wide range of available media.

Contact

Dr. Dmitry Suslov

Group Leader
German Aerospace Center (DLR)
Institute of Space Propulsion
Rocket Propulsion Systems
Im Langen Grund, 74239 Hardthausen
Germany