Technical Applications of Space 3D Printing

Metals with complex heat dissipation structures made using 3D printing can withstand high temperatures. NASA’s Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project is an additive manufacturing technology, using metal powder and laser 3D printing rocket engine parts (Fig. 7.1). This method, known as blown powder directed energy deposition, reduce the cost of producing large complex engine parts (such as nozzles and combustion chambers) and shorten delivery times. The printing method injects metal powder into a molten metal pool heated by a laser (also known as a melt pool), the nozzle that blows out the powder and the laser optics are integrated into a print head, and this print head is connected to a robotic arm. The print head moves according to a computer-determined pattern, building one layer at a time. This manufacturing method has many advantages, including the ability to produce very large products. It can also be used to print very complex parts, including engine nozzles with internal coolant channels. Rocket engine nozzles with internal coolant channels run low-temperature propellant through these channels to help the nozzle maintain a safe temperature. Manufacturing nozzles in a traditional way is a challenging process that may take a long time. Blown powder directed energy deposition additive manufacturing can create large-scale parts with complex internal features, which was difficult to achieve before. It can greatly reduce the time and cost of manufacturing cooling nozzles with internal channels and other key parts of rockets.