Aerojet Rocketdyne Successfully Tests First 3D-Printed Rocket Part 

In collaboration with Aerojet Rocketdyne, NASA recently created and tested a rocket engine injector made entirely through 3D printing.  Their successful testing, conducted at NASA’s Glenn Research Center in Cleveland, Ohio, could save companies both time and money due to the simplified manufacturing process.

Aerojet Rocketdyne created the rocket engine injector by using laser melting manufacturing technology.  This technology uses high-powered laser beams to melt and fuse metallic powders together layer by layer to form three-dimensional objects.

Michael Gazarik, NASA’s associate administrator for space technology in Washington said, "NASA recognizes that on Earth and potentially in space, additive manufacturing can be game-changing for new mission opportunities, significantly reducing production time and cost by 'printing' tools, engine parts or even entire spacecraft.  3-D manufacturing offers opportunities to optimize the fit, form and delivery systems of materials that will enable our space missions while directly benefiting American businesses here on Earth."

Normally it would take over a year to build this engine component, but with additive manufacturing it can be built in less than four months.  In addition, the new process reduces costs by a staggering 70 percent.

Jeff Haynes, Aerojet Rocketdyne’s additive manufacturing program manager said that the injector represents a huge advancement in the application of additive manufacturing. "The injector is the heart of a rocket engine and represents a large portion of the resulting cost of these systems. Today, we have the results of a fully additive manufactured rocket injector with a demonstration in a relevant environment.”

The Air Force Research Laboratory at Edwards Air Force Base in California was also able to assist on the project.  They provided a high-pressure facility where pre-test data was collected to give insight into the spray patterns of additively manufactured injector elements. 

The manager of the Manufacturing Innovation Project at Glenn Research Center, Carol Tolbert, said, “Hot fire testing the injector as part of a rocket engine is a significant accomplishment in maturing additive manufacturing for use in rocket engines. These successful tests let us know that we are ready to move on to demonstrate the feasibility of developing full-size, additively manufactured parts."