Farsoon Technologies, in collaboration with Deep Blue Aerospace, has achieved a significant milestone in large-scale rocket combustion chamber manufacturing. The joint effort resulted in the development of a 600 x 780 mm chamber tailored for commercial launch projects.
Engineers from both companies dedicated extensive time to address critical technical challenges and undergo thorough testing and verification processes. Through meticulous optimization of machine and process parameters, including enhancements to the optical system, scanning strategy, and powder recoating, production efficiency skyrocketed. The manufacturing time for the combustion chamber plummeted from 327 hours to a mere 96.5 hours, marking a 338% increase in build efficiency.
The collaboration’s success is pivotal for Farsoon as it aims to revolutionize production efficiency in large-format metal powder bed fusion solutions. Key innovations encompass advanced multi-laser scanning strategies, optimized gas flow design, and refined control systems. These developments not only ensure superior internal metallurgical quality but also enhance communication efficiency between lasers and minimize machine downtime.
Notably, Farsoon’s tailored processing parameters have enabled the attainment of smooth surfaces critical for optimizing flow resistance within the combustion chamber’s intricate cooling channels.
The culmination of this collaborative effort signifies a hefty leap forward in rocket propulsion system manufacturing, with implications extending beyond commercial launch projects. It underscores the transformative potential of additive manufacturing in the aerospace industry’s manufacturing landscape.
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