ArianeGroup has recently conducted several tests of its 3D printed combustion chamber. From May 26th and June 2nd, the new combustion chamber has been tested 14 times at the DLR German Aerospace Center’s Lampoldshausen testing facility.

As a reminder, last year, 14 technological building blocks for future liquid propellant rocket engines were validated by ArianeGroup. Following these tests, the teams are optimistic regarding the preparations for the future development of very-low-cost rocket engines.

Specifications and manufacturing of the combustion chamber

This 3D-printed combustion chamber was manufactured and tested under ESA’s Expander-Cycle Technology Integrated Demonstrator (ETID) project, part of ESA’s Future Launchers Preparatory Programme. It is a full-scale demonstrator for a launcher upper stage engine. This demonstrator incorporates the very latest propulsion technologies and is designed to validate innovative manufacturing technologies, materials and processes, such as 3D printing (by laser fusion and projection), laser ignition, and the use of low-cost materials.

This combustion chamber features numerous innovations, such as the low-cost copper alloy cooling channels and an outer jacket made by “cold gas” spraying. Also, the combustion chamber includes a single-piece injection head produced by laser fusion 3D printing using all the injectors. This is an ideal solution for significantly reducing engines construction times and production costs in the future.

ArianeGroup’s use of 3D Printing

ArianeGroup already uses 3D printing to manufacture many components for Ariane 6 engines. Apart from significantly reducing costs and shortening production cycles, the use of 3D printing has made it possible to integrate the Auxiliary Power Unit (APU) into Ariane 6, thus increasing the launcher’s unrivalled ability to adapt to the needs of different missions.

Today, the company continues to develop its expertise in the field of 3D printing for launcher propulsion systems through various programs, the latest announced being the Future Launchers Preparatory Program (FLPP), a program whose goal is to improve the competitiveness of future European launchers by creating mature technical solutions that are ready for rapid deployment, developing products with lower cost, effort, and risk.

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