In a remarkable stride towards the future of space exploration, SAB Aerospace (SAB) is breaking new ground with its innovative use of Direct Energy Deposition (DED) technology. The company has crafted the first demonstrative model of one of the largest and most complex rocket nozzles ever produced, living up to their motto, “Crafting the Future of Space One Layer at a Time.” This cutting-edge nozzle design marks a significant step forward in enabling deep space missions.
The aerospace industry has seen tremendous evolution since the days of the Wright brothers’ aviation pioneers, credited with inventing, building, and flying the world’s first successful airplane. With the advent of new technologies, the sector has continuously advanced, improving manufacturing processes along the way. One of the most transformative technologies in recent years is additive manufacturing, which has revolutionised the way aerospace components are designed, tested, and produced.
This article delves into how SAB Aerospace has harnessed additive manufacturing to develop a highly intricate rocket nozzle, a feat that exemplifies the industry’s progress.
Additive manufacturing, commonly known as 3D printing, involves creating a three-dimensional object from a digital file. While not all 3D printing methods fall under additive manufacturing, this technique allows manufacturers to fabricate complex shapes and structures that would be challenging to achieve with traditional methods.
The Direct Energy Deposition (DED) process utilised by SAB Aerospace involves the use of a laser to create a melt pool, into which metal powder is blown. As the powder melts and then cools, it forms a solid material, with the entire process controlled by the 3D motion of a robotic system.
This approach enables the production of larger components compared to laser powder bed fusion and is instrumental in pushing the boundaries of what is possible in aerospace manufacturing, offering new possibilities for large-scale, complex parts.
But, how exactly is SAB Aerospace using additive manufacturing to revolutionise the aerospace industry?
Additive manufacturing is rapidly becoming the standard for producing precision-engineered aerospace components. Unlike traditional subtractive manufacturing, which involves cutting shapes from a solid material using lasers or lathes, additive manufacturing builds three-dimensional objects by layering materials. This technique mirrors the process seen in domestic 3D printing devices but on an industrial scale, capable of producing complex and highly detailed parts. SAB Aerospace stands at the forefront of this technological revolution, particularly in the application of Direct Energy Deposition (DED) technology. This advanced method enables the production of components with unparalleled precision and complexity, offering significant advantages in terms of enhancing capabilities and reducing costs. The use of DED technology is particularly transformative for manufacturing rocket nozzles—a process that, traditionally, is fraught with challenges and time-consuming intricacies.
By leveraging DED additive manufacturing, SAB Aerospace can produce large-scale components with intricate internal features, previously unattainable with conventional manufacturing techniques. This not only streamlines the production process but also opens up new possibilities for the design and functionality of aerospace components, marking a significant leap forward in the industry.
So, what makes SAB Aerospace’s nozzle truly exceptional?
SAB Aerospace in cooperation with AVIO has chosen to utilise the Direct Energy Deposition process along with Inconel® to develop their unique rocket engine nozzle. This combination results in a lighter, more efficient nozzle compared to conventional designs, which is crucial for deep space missions that require maximised payload capacities.
Inconel® is highly favoured in aerospace applications due to its exceptional and versatile corrosion resistance across a wide range of temperatures and pressures. This property is particularly valuable in the harsh conditions of space, making it a preferred material in the fabrication of space nozzles.
Designed specifically for high-performance rocket engines, Inconel® is a nickel-based superalloy optimised for high strength, excellent thermal conductivity, and superior creep resistance. These attributes enable the material to withstand significant stress and strain at elevated temperatures, while its good low-cycle fatigue properties help prevent material failures.
Inconel® can endure temperatures up to 40% higher than those tolerated by traditional alloys, which enhances the performance and reusability of components. In extreme environments, the ease of fabrication and robust strength of Inconel® sets it apart from other materials, improving heat transfer efficiency and reducing weight. The alloy is particularly chosen for its high strength, uniform corrosion resistance, resistance to stress cracking, and excellent pitting resistance in water temperatures ranging from 500° to 600°F (260–316°C). Furthermore, its high allowable design strength at elevated temperatures, especially between 1200° and 1400°F (649–760°C), makes it the material of choice for this application.
As humanity sets its sights on ambitious goals like Moon to Mars missions and other deep space expeditions, the ability to send more cargo to distant destinations becomes increasingly crucial. Space missions constantly seek innovative solutions to meet these demanding requirements.
At SAB Aerospace, we are dedicated to driving advancements in the space sector. Our team is fervently committed to developing cutting-edge products and delivering innovative services that push the boundaries of space exploration.
The use of novel alloys can play a pivotal role in this endeavour by enabling the production of lightweight rocket components that can endure high structural loads.
In space exploration, every gram counts; reducing mass is critical for the success of future deep space missions. By maturing additive manufacturing technologies and incorporating advanced materials, projects like ours at SAB Aerospace will facilitate the evolution of new propulsion systems, in-space manufacturing capabilities and the necessary infrastructure.
Our mission is to provide solutions that inspire, transform, and contribute significantly to the advancement of space exploration.
While various aerospace companies are still evaluating the potential of novel alloys and DED additive manufacturing, SAB Aerospace has already embraced these technologies. Our focus is on developing lightweight, additively-manufactured alloy rocket nozzles, a critical component in realising more efficient and capable space missions. Through our pioneering efforts, we aim to lead the industry in creating innovative and practical solutions that not only meet but exceed the demands of future space exploration.
What further distinguishes SAB Aerospace’s nozzle is the innovative design incorporating small internal channels. These channels are crucial for maintaining the nozzle’s temperature, preventing it from melting under intense operational conditions. Unlike traditional manufacturing methods that might require thousands of individually joined parts, SAB Aerospace’s nozzle is constructed as a single piece. This not only reduces the number of bonds but also significantly cuts down on manufacturing time.
The use of the Laserdyne® 795XL metallic 3D printer (from Prima Additive) with DED technology at SAB Aerospace enables the production of large, complex components with unparalleled speed, precision, and efficiency.The printer’s spacious build volume of more than one cubic metre allows for the creation of custom specifications that are difficult, if not impossible, to achieve with other manufacturing techniques.
This achievement highlights SAB Aerospace’s dedication to pushing the boundaries of aerospace engineering through advanced manufacturing technologies.
