Monolithic 3D Printed Rocket Engine Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional rocket engine manufacturing involves assembling thousands of subcomponents, which increases mass, cost, and complexity, and requires extensive manpower and time.
Innovation Solution
A single piece, 3D printed, integrated propulsion engine is developed using additive manufacturing methods, where all components such as the combustion chamber, injector plate, igniter, nozzle, and regenerative cooling channels are fused and integrated in a single creation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional assembly methods with multiple subcomponents are used, then manufacturing precision and reliability can be maintained through careful welding and bracing, but device complexity and manufacturing time increase significantly
Solution Approach 1:
The patent merges multiple separate engine components (combustion chamber, injector plate, nozzle, cooling channels) into a single monolithic structure manufactured by additive manufacturing. This eliminates the need for welding and bracing between components, reducing device complexity from thousands of subcomponents to one integrated piece while maintaining reliability through seamless construction.
Solution Approach 2:
The single piece engine structure performs multiple functions simultaneously: the integrated design combines combustion chamber, fuel injection, thrust generation, and cooling functions in one component. This multi-functionality reduces the number of separate parts needed while maintaining all necessary engine functions.
2Strength
If multiple separate components are assembled using welding and bracing, then structural strength can be achieved, but manufacturing cost and manpower requirements increase
Solution Approach 1:
By combining all engine components into one additively manufactured piece, the patent eliminates costly welding and bracing operations. The seamless monolithic structure achieves structural strength without the need for joining operations, significantly reducing manufacturing cost and manpower requirements.
Solution Approach 2:
The patent replaces traditional mechanical assembly methods (welding, bracing, bolting) with additive manufacturing technology. This substitution eliminates the need for complex joining operations while maintaining structural integrity, reducing both cost and manufacturing complexity.
3Reliability
If traditional manufacturing methods with multiple parts are used, then component reliability can be ensured through quality control, but production time and assembly complexity increase
Solution Approach 1:
The patent combines all engine components into a single additively manufactured piece, eliminating time-consuming assembly operations. The one-step manufacturing process produces the complete engine structure without sequential assembly, significantly increasing productivity while maintaining reliability through controlled additive manufacturing.
Solution Approach 2:
The additive manufacturing process performs all necessary material deposition and structural formation in a single continuous operation before final completion. This preliminary action of building the entire structure in one process eliminates subsequent assembly steps, accelerating production time.
4Reliability
If thousands of subcomponents are assembled carefully, then engine performance can be optimized, but mass and cost of the engine increase
Solution Approach 1:
By merging all engine components into one integrated structure, the patent eliminates the mass of multiple separate parts, fasteners, welds, and bracing. The single piece design achieves optimal engine performance with reduced mass compared to assembled multi-component engines.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The 3D printed engine reduces the number of subcomponents, decreases mass, lowers production costs, and streamlines the manufacturing process, enabling faster turnaround times and more frequent launches.
Implementation Method 1
selectively fusing powders in a powder bed by melting the powder using a laser source
Data Source
AI summary
Disclosed herein is a single piece, integrated, light weighted, cost-effective 3D printed engine for space vehicles. FIG. 5 illustrates an integrated engine that comprises a combustion chamber to burn the fuel, an injector plate (504) to inject the fuel to the combustion chamber, an igniter (502) to ignite the fuel mixture, a nozzle (506) to pass hot gas to produce thrust and cooling channels (508) for regenerative cooling, where all these components are fused to form a single piece integrated engine. The engine of the present invention eliminates the need of assembling the individual components. Further, the engine is additively manufactured with high grade aerospace materials. Thus, the cost and mass of the engine is reduced when compared to traditionally manufactured engines, which leads to frequent missions.