Improve Performance and Fuel Efficiency, Increase Reliability and Reduce Manufacturing Costs
20:1
component reduction
$2M
average annual fuel savings
2x
increase in component life

Improving Performance for Space Launch, Create More-Efficient Rocket and Satellite Engines

Smile Project test fire

German Aerospace Center Smile Project Test Fire. This work is performed within the ‘SMall Innovative Launcher for Europe’ project. SMILE, coordinated by NLR, has received funding from the European Union’s ‘Horizon 2020 research and innovation program’ under grant agreement No 687242.

Propulsion components are fundamental to space launch vehicle performance by utilizing optimally designed hardware, which offers the best overall system efficiency. Injectors, thrust chambers, nozzles, and turbopumps are components and systems with complex internal structures that promote combustion and heat transfer to burn fuel and oxidizer efficiently, which requires the highest quality components made of high strength, heat-resistant superalloys. 

All of this is now possible thanks to direct metal 3D printing solutions and material expertise from 3D Systems. 3D print nozzles, fuel pre-burners, valves, manifolds, and other propulsion systems that maximize space and material usage. Space launch and propulsion experts can design monolithic multi-material combustion devices that perform more efficiently than ever before. Fewer components reduce manufacturing costs, eliminates complex assemblies, and increases overall performance and reliability. In addition, these optimized products can be developed in far less time to deliver more effective components to market faster.

Solve the Challenges Associated with Propulsion Design

  • 3d systems laserform ti gr5 (a) dmp hydraulic manifold gf post machined alternate

  • Reduce Parts Count

    Consolidate traditionally complex assemblies into monolithic propulsion system designs. -- Fewer quality controls required -- Simplified supply chain -- Shorter integration time
  • 3D printed Aerospace fuel injectors

  • Simplify Fluid Management

    Our metal additive manufacturing solutions allow for the production of propulsion system components with freeform fluid channel designs. This reduces turbulence, pressure fluctuations, weight, and space requirements.

  • Improve System Efficiency

    Additive manufacturing enables propulsion and vehicle design engineers with unprecedented design flexibility. The technology allows for development of novel orifice shapes, heat exchangers, and mixing chambers, thus optimizing staged combustion cycles for maximum performance and efficiency.

  • 3D printed combustor component
  • semiconductor technology transfer image

  • Reduce Manufacturing Costs and Lead Time

    In traditional manufacturing, heat-resistant superalloys used in propulsion devices, such as thrust chambers or turbomachinery combustors, present challenges in machining, including short tool life and high material waste. Additive manufacturing has no difficulty with these materials, regardless of geometry or superalloy used. Further, replacing multipart assemblies (such as injectors, swirlers, and heat exchangers) with monolithic parts improves manufacturing yield and reduces labor costs.

3D Systems Delivers Increased Performance and Productivity to Manufacturers

  • Application Development

    Through our Application Innovation Group, we leverage years of space launch and metal additive manufacturing expertise to help find optimized solutions for your applications. The support we provide enables an engineering and design approach that repeatedly meets strict requirements.

  • Metal Additive Expertise

    With our combination of metal hardware, software, and materials, we offer solutions with unprecedented design flexibility, economics, and reliability that traditional manufacturing cannot match.

  • Production Capability

    With our production facilities, we can be your agile manufacturing arm, helping you transition from prototype to production while offering increased supply chain capacity and flexibility. We also offer on-demand printing services available to you 24/7.

More Aerospace and Defense Applications

Thales Bracket Close-Up Aerospace

Lightweight Brackets
Laserform Heat Exchanger Closeup for Aerospace

Heat Exchangers
Investment Casting Patterns for Aerospace Applications Thumbnail

Investment Casting

Learn More About Our Solutions for Propulsion Applications

Manufacture metal parts with scalable DMLS with removable build chamber for continuous printing

DMP Factory 500

Robust, high quality metal 3D printing with integrated powder management

LaserForm Ni718 (A) DMP Combustion Chamber

LaserForm Ni718 (A)

Metal 3D print material resistant to oxidation, corrosion and extremely high-temperatures

3D Systems 3DXpert hero image

3DXpert

All-in-One Integrated Software for Industrial Additive Manufacturing

3D Systems Laserform Ni625 Nozzle

LaserForm Ni625 (A) Metal 3D Print

Excellent corrosion resistance, high strength and heat resistance

Talk to an Expert

NoSupports enables metal powder-bed printing without support structures.

Powered by 3DXpert software, NoSupports expands the design envelope, accelerates design cycles, and unlocks new applications. 

  • Application Innovation Group

    Our team can help you solve your most difficult design and production challenges with additive manufacturing solutions. Together we’ll identify your needs, working with you to optimize your designs, prototype, validate and define a manufacturing flow.
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