How additive manufacturing helped launch SpaceX

SpaceX is considered one of the most exciting companies of the 21^st century, and with the rise of additive manufacturing (AM), industrial equipment supplier Kingsbury UK takes a look at how the US space company applies the technology.

The US space company has a track record of proving they can achieve incredible feats: from being the first private company to launch an orbital rocket, to being the first organisation in history to land a huge, first-stage rocket upright on a barge in the middle of the ocean. This article will focus on how SpaceX’s AM adoption is being used to push the boundaries of what’s possible in manufacturing through cutting-edge technologies.

How does SpaceX use AM?

SpaceX has been using AM increasingly in its production to optimise processes and produce parts that aren’t possible with conventional manufacturing methods.

SpaceX is a champion of vertical integration: this means that they bring in raw material at one end of the factory and a fully manufactured rocket comes out the other end. AM allows the implementation of this philosophy, for example a typical cast part needs to be designed in CAD, a complex mould then needs to be manufactured, a test casting is done at the foundry and if necessary, any alterations to the mould must be made before manufacturing can commence in earnest.

AM eliminates this entire process as the design and manufacture of a complex metal part can be done in the SpaceX factory without having to outsource to other suppliers. This reduces cost, safeguards intellectual property, allows for stricter quality control and reduces lead times.

SpaceX has been continuously evaluating the benefits of 3D printing and perfecting the techniques required to develop and manufacture flight hardware. With innovation and efficiency at the core of SpaceX, it’s no wonder its been one of the first companies in the sector to embrace AM as a major part of its production.

What technology does SpaceX use?

SpaceX makes use of direct metal laser sintering (DMLS). This type of AM works by laying down thin layers of metal powder in a heated chamber. A laser then traces out the 2D cross section of the part. The laser brings the temperature of the powder above its melting point and the metal melts. The next layer is then added on top and the process is repeated, thus sintering each layer to the previous one. SpaceX prints also run through cooling cycles.

AM projects

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SuperDraco Engine Chamber

The SuperDraco rockets are designed primarily as an emergency launch escape rocket in the unlikely event the first stage of the rocket fails explosively. These rockets need to accelerate the crew capsule with an incredible thrust of 120,000 pounds in order to safely escape the blast.

The engine chamber of the SuperDraco was 3D printed out of Inconel; a superalloy used in the aerospace industry for high-stress parts. This component was put through a variety of tests such as multiple starts, high temperature and extended firing durations to name a few. These tests proved that the engine chamber was ready for use on a Dragon 2 capsule rated for human flight.

[caption id="attachment_43415" align="aligncenter" width="1500"] SpaceX's Merlin 1D engine, which powers the Falcon 9 rocket[/caption]

Main Oxidiser Valve Body

In 2014 one of the Falcon 9 rocket's Merlin 1D engines contained a 3D printed main oxidizer valve (MOV) body that was successfully tested. The component managed to withstand cryogenic temperatures at excessive pressures and high vibration

This component was also manufactured within 2 days, a record time when compared to the typical 2-month cycle of traditional mould making and casting. After various tests and qualifications this part was allowed to replace cast parts on all Falcon 9 flights.

These critical components are just the first step in a future dominated by AM, due to SpaceX’s willingness to adopt new technology. As long as it benefits the ultimate goal there will be more and more parts in SpaceX’s inventory using these techniques.

As the technology matures the number of applications will begin to expand and any technological developments made by companies like SpaceX will trickle down into other industries. With the AM torch carried by SpaceX the future of the technology looks bright.

Kingsbury UK www.kingsburyuk.com/guide/additive-in-aerospace