SAB Aerospace 3D prints complex nozzle using DED technology

SAB Aerospace (SAB) has crafted the first demonstrative model of one of the largest and most complex rocket nozzles that the company has ever produced using DED technology from Prima Additive. The company’s motto is, appropriately, “Crafting the Future of Space One Layer at a Time.”

By leveraging DED additive manufacturing, SAB Aerospace can produce large-scale components with intricate internal features, previously unattainable with conventional manufacturing techniques. This not only streamlines the production process but also opens up new possibilities for the design and functionality of aerospace components.

The use of the Laserdyne 795XL metal 3D printer (from Prima Additive) with DED technology at SAB Aerospace enables the production of large, complex components with unparalleled speed, precision, and efficiency. The printer’s build volume of more than one cubic meter allows for creating custom specifications that are difficult, if not impossible, to achieve with other manufacturing techniques.

SAB Aerospace in cooperation with AVIO used the Inconel superalloy material to develop its metal DED 3D printed rocket engine nozzle. This combination results in an even lighter, more efficient nozzle than conventional designs, which is crucial for deep space missions requiring maximized payload capacities.

Designed specifically for high-performance rocket engines, Inconel is a nickel-based superalloy optimized for high strength, excellent thermal conductivity, and superior creep resistance.  Inconel is highly favored in aerospace applications due to its corrosion resistance across various temperatures and pressures. This property is particularly valuable in the harsh conditions of space, making it a preferred material in the fabrication of space nozzles.

These attributes enable the material to withstand significant stress and strain at elevated temperatures, while its good low-cycle fatigue properties help prevent material failures. Inconel can endure temperatures up to 40% higher than those tolerated by traditional alloys, which enhances the performance and reusability of components.

The alloy is particularly appreciated for its high strength, uniform corrosion resistance, resistance to stress cracking, and excellent pitting resistance in water temperatures ranging from 500° to 600°F (260–316°C). Furthermore, its high allowable design strength at elevated temperatures, especially between 1200° and 1400°F (649–760°C), makes it the material of choice for this application.

What further distinguishes SAB Aerospace’s nozzle is the innovative design incorporating small internal channels. These channels are crucial for maintaining the nozzle’s temperature, preventing it from melting under intense operational conditions. Unlike traditional manufacturing methods that might require thousands of individually joined parts, SAB Aerospace’s nozzle is constructed as a single piece. This reduces the number of bond and significantly cuts down on manufacturing time.

While various aerospace companies are still evaluating the potential of novel alloys and DED additive manufacturing, SAB Aerospace has already embraced these technologies. Its focus is now on developing lightweight, additively manufactured alloy rocket nozzles, a critical component in realizing more efficient and capable space missions. Through these efforts, the company aims to lead the industry in creating innovative and practical solutions that not only meet but exceed the demands of future space exploration.