Aurora Labs validates performance of 3D printed engine

Aurora Labs (A3D), an Australian industrial technology and innovation company, has validated the performance and functionality of its ‘in-house’ 3D printed engine during a maiden aerial test flight for its 200 Class micro gas turbine, which performed to specification – producing 22kg of thrust at full throttle. The company deployed the engine in a sub-25 kg class, unmanned airframe, with a 2.79m wingspan and a top speed of 270km per hour.

“We are thrilled to announce a significant milestone in the micro gas turbine project, with our maiden flight now complete. A3D’s development of the 3D printed turbine underscores our commitment to innovation, positioning the company at the forefront of micro gas turbine technology development and advancing new frontiers. The team’s swift progress to the initial flight stage has enabled us to break through into new markets and applications for 3D printing, fostering future growth and increasing value for A3D shareholders,” said Rebekah Letheby, CEO of Aurora Labs.

Key features of the Aurora 200 Class micro gas turbines include 20kg of thrust; an integrated electronic control unit, a brushless fuel pump for fuel efficiency, and excellent combustion temperatures for optimal fuel burn; a reduction in total weight thanks to 3D printing; part amalgamation for ease of assembly and lower cost of manufacturing; and an engine designed, printed, and built completely in Australia.

Since late 2023, the micro gas turbine design has undergone extensive detailed prototyping, with multiple designs produced, 3D printed, and bench tested to reach this stage. The 3D printing workflow supports multiple design iterations due to the ease of production of the upgraded designs.

The company is satisfied that it is now ready to move into further test work in an aerial environment. Real-world flight testing will further stress test the micro gas turbine at both altitude and temperature, ensuring the design and performance are optimized to suit this propulsion application.

Results from the successful test flight will be provided to potential customers in the industry and defense to foster potential commercial engagement.

The company is also planning to test larger turbines to expand the diversity of applications in the gas turbine markets.