In a significant leap forward for space exploration technology, NASA has successfully tested an RS-25 rocket engine featuring a major component created through 3D printing. This achievement marks a pivotal moment in the potential for manufacturing entire rocket engines using this innovative technology.
This successful test is a vital step in the short term towards reducing the costs associated with engines designed for NASA's new heavy-lift rocket, the Space Launch System (SLS). The SLS is central to NASA's ambitious deep space exploration plans, including the much-anticipated manned mission to Mars.
Unprecedented Power in Rocketry
The Space Launch System is poised to become the most powerful rocket ever built, with a total thrust exceeding that of the Saturn V, the rocket that powered the historic Moon missions. The development of the SLS is ongoing, with plans to upgrade the vehicle with even more powerful versions over time.
Currently, the rocket features two five-segment Solid Rocket Boosters, powered by RS-25 engines, capable of generating a total thrust of 32,000 kiloNewtons. To put this into perspective, one newton is the force needed to accelerate one kilogram of mass at the rate of one meter per second squared in the direction of the applied force. These boosters will be the largest solid-propellant motors ever flown.
A significant challenge in rocket engine performance is the potential for intense vibrations during flight, caused by propellant in the feed lines. The newly tested 3D printed component, known as a Pogo accumulator, functions as a shock absorber to mitigate these vibrations and ensure the rocket's flight stability. The name is inspired by a child's Pogo stick.
3D printing technology has allowed for the elimination of over 100 welds in the Pogo accumulator, speeding up production and reducing manufacturing costs by nearly 35 percent. Fewer welds mean fewer inspections and less rework, which are typically required due to standard manufacturing error rates.
Collaborative Innovation
This advancement was made possible through a partnership between NASA and Aerojet Rocketdyne of Canoga Park, California. The trials of the 3D printed hardware met all acceptance criteria for performance, reliability, and safety. Andy Hardin from NASA’s Marshall Space Flight Center in Huntsville stated, “As we build future RS-25s, NASA and our partners are leveraging innovative manufacturing techniques, including additive manufacturing, or 3D printing, to make the engines more affordable.”
Hardin further emphasized, “3D printing is transforming manufacturing, and the pogo accumulator is the first of many components that can be produced more quickly and cost-effectively.”
The new components are not limited to new engines; NASA plans to retrofit its fleet of 16 heritage engines with the new controllers. Future enhancements will include main combustion chambers, nozzles, ducts, valves, electrical systems, and running gear, all benefiting from cost-effective improvements made possible by 3D printing.