Farsoon has developed a specialized 3D printing system for producing large copper alloy components for aerospace applications. The company’s new FS621M-Cu system, built on their existing large-format platform, features four 1000W ytterbium fiber lasers designed to work with highly reflective materials like CuCrZr. This technology addresses the historical challenges of using copper in additive manufacturing due to its high reflectivity to near-infrared lasers.
In partnership with an aerospace manufacturer, Farsoon has enabled the production of thrust chamber liners for liquid rocket engines. These components, which require complex cooling channels and must withstand extreme conditions, have traditionally been manufactured through labor-intensive processes. The new approach uses laser powder bed fusion to create monolithic structures with optimized cooling channels, eliminating multiple assembly steps.
The technology incorporates several technical solutions to overcome copper’s challenging properties, including an anti-reflective chamber coating and smart thermal management systems. In August 2023, the system produced a 600mm diameter by 850mm height thrust chamber liner with near-theoretical density (8.86 g/cm³) and thermal conductivity exceeding 345 W/(m·K). X-ray scans confirmed the precision of the internal cooling channels.
Testing of the printed components showed impressive thermal properties, with thermal diffusivity of ≥95 mm²/s and specific heat capacity of ≥0.35 J/(g·K). The mechanical properties of as-printed tensile specimens also demonstrated excellent results according to the company.
The manufacturing process developed in 2023 has led to significant improvements in production efficiency. Components now exceed design specifications by more than 50% while reducing lead times to 15-20 days compared to traditional methods. The approach has also reportedly achieved cost reductions of up to 75%, making it a potentially valuable solution for aerospace manufacturers requiring large copper alloy components.
Source: farsoon-gl.com