The Air Force Research Laboratory’s (AFRL) Rocket Propulsion Division has used directed energy deposition (DED) to make a unique single-block rocket-engine thrust chamber.
With their DED method, they have fused metal powder with high-power laser beams under controlled conditions, surpassing traditional techniques like laser powder bed fusion (LPBF).
“AFRL’s investments in early advanced manufacturing techniques allow us to explore new areas of the design space for rocket engines and enable quicker design to testing cycles, from concept on a whiteboard to field evaluation,” said Dr. Javier Urzay, Chief of the Combustion Devices Branch.
“This technology enables us to pursue complex engine designs with fewer iterations, employing shape optimization, lightweight materials, and rapid manufacturing techniques.”
While additive manufacturing offers cost and time benefits, overcoming technological challenges remains crucial. AFRL, in collaboration with industry and government partners like NASA, continues to address material durability under extreme conditions. AFRL collaborates closely with the U.S. space industry, aiming to optimize complex engine designs and streamline manufacturing processes.
The AFRL Rocket Propulsion Division aims to utilize additive manufacturing techniques to enhance the production of both liquid and solid rocket motors.
Source: afrl.af.mil
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