Rocket Engine Injector Assembly via Additive Manufacturing

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Solution Overview

Problem

Traditional rocket engine manufacturing techniques are complex and costly, involving intricate assembly procedures for thrust chambers, injectors, and turbopump systems, which complicate design and increase production time and costs.

Innovation Solution

The use of additive manufacturing techniques, specifically direct metal laser sintering, to produce rocket engine components such as thrust chambers, injectors, and turbopumps, allowing for complex geometries and reduced assembly complexity by creating sintered metal structures with varying surface roughness and particle diameters to enhance cooling and performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If traditional manufacturing techniques are used for thrust chambers and injectors, then structural integrity is maintained, but assembly complexity and production costs increase

Engineering Contradiction:

Improveassembly complexityVSAvoidproduction cost

Core Design Contradiction:

Device complexityVSEase of manufacture

Solution Approach 1:

The patent combines multiple separate components (thrust chamber walls, coolant flow passages, injector elements) into a single integrated structure manufactured via additive manufacturing. This merging eliminates complex assembly procedures while maintaining structural integrity, directly resolving the contradiction between assembly complexity and manufacturing ease.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent utilizes additive manufacturing technology to change the manufacturing parameter from traditional subtractive or formative methods. This parameter change enables complex geometries to be produced more simply, reducing assembly complexity while managing production costs through advanced manufacturing techniques.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If uniform surface roughness is used in coolant flow passages, then manufacturing is simplified, but heat transfer performance and pressure drop characteristics are compromised

Engineering Contradiction:

Improvesurface roughness controlVSAvoidheat transfer efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies different surface roughness characteristics to different regions of the coolant flow passages. By varying the particle diameter of metal powder in specific zones during additive manufacturing, the invention optimizes heat transfer performance in high-heat-flux areas while maintaining smoother surfaces elsewhere, resolving the contradiction between manufacturing precision and heat transfer efficiency.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent introduces dynamic variation in surface roughness along the coolant flow path. By changing particle diameter as a function of position, the invention creates adaptive surface characteristics that optimize heat transfer where needed while managing pressure drop, thereby improving overall productivity without sacrificing manufacturing control.

Inventive Principle:

Principle #15Dynamics

3Adaptability or versatility

If complex geometries are manufactured using traditional methods, then design flexibility is limited, but production time and costs increase

Engineering Contradiction:

Improvedesign flexibilityVSAvoidproduction time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The patent changes the manufacturing parameter from traditional methods to additive manufacturing, enabling complex geometries to be produced directly from digital models. This parameter change eliminates time-consuming machining and assembly operations while providing full design flexibility for complex thrust chamber and injector geometries.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent performs preliminary design and simulation of complex geometries using computational tools before manufacturing. This preliminary action allows optimization of complex structures in virtual space, reducing iteration time and enabling rapid production of finalized complex geometries through additive manufacturing.

Inventive Principle:

Principle #10Preliminary action

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

This approach simplifies the assembly and design of rocket engine components, reduces production costs, and enhances cooling performance by varying surface roughness and particle diameters, leading to improved heat transfer and reduced pressure drop, while maintaining structural integrity.

Implementation Method 1

direct metal laser sintering

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 2

direct metal laser sintering to produce rocket engine components

Methodology Applied

Scientific EffectSintering: Sintering

Implementation Method 3

coolant flow passages that extend from a first end of the thrust chamber to a second end of the thrust chamber

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 4

enhances cooling performance by varying surface roughness and particle diameters, leading to improved heat transfer

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Data Source

PatentUS12196159B1Rocket engine injector

Publication Date: 2025.01.14 ROCKET LAB USA INC

AI summary

Disclosed herein are various technologies pertinent to rocket engines, including injector, thrust chamber, and electrical turbopump devices that may be combined to provide a more efficient rocket engine.