NASA's revolutionary aluminum rocket nozzles, created through 3D printing in collaboration with Elementum 3D, mark a significant step towards efficient and lightweight rocket components for future deep space missions. (representative image) (pixabay)

3D Printing Technology Used to Create Aluminum Rocket Nozzles by NASA

In a partnership with Elementum 3D, NASA has successfully utilized 3D printing technology to create an innovative aluminum rocket engine nozzle. This remarkable achievement is a significant milestone for NASA’s RAMFIRE project, which is supported by funding from NASA’s Space Technology Mission Directorate (STMD).

The aluminum used in this project is a specially designed variant called A6061-RAM2 that can withstand high temperatures and welding, overcoming the typical limitations of aluminum in rocket engine construction.

Traditional rocket nozzles consist of numerous individually connected parts, but the RAMFIRE nozzle is manufactured in one piece, which significantly reduces the number of connections and manufacturing time.

The nozzle has small internal channels to keep it cool and prevent melting, which allows the use of aluminum in its construction.

RPM Innovations in Rapid City, South Dakota used this innovative aluminum and a special powder with laser powder-directed energy deposition (LP-DED) technology to build the RAMFIRE nozzles.

NASA is looking to send more cargo to deep space destinations as part of its Moon to Mars mission, and a lightweight yet durable aluminum alloy could play a key role in achieving that goal.

Two RAMFIRE nozzles successfully completed hot fire tests with different fuel configurations to demonstrate their ability to operate in the demanding environments of deep space.

The project also uses RAMFIRE aluminum material and an additive manufacturing process to build other advanced components, such as a 36-inch diameter aerospike nozzle and a vacuum-jacketed tank for cryogenic fluid applications.

NASA and its partners are actively sharing their knowledge and processes with commercial stakeholders and academia to explore the potential applications of this new alloy and LP-DED additive manufacturing process in a variety of aerospace and satellite components. This development holds great promise for the future of space exploration and propulsion systems.