‘In fall 2023’ as NASA put it, the RDRE was tested at the agency’s Marshall Space Flight Center in Huntsville, Alabama. The engine successfully completed a 251-second ‘hot fire test,’ said NASA. The engine generated more than 5800 pounds of thrust.

On December 20, 2023, NASA successfully tested a 3D-printed rocket engine for 251 seconds, producing more than 5,800 pounds of thrust. The engine, called the Rotating Detonation Rocket Engine (RDRE), was tested at NASA’s Marshall Space Flight Center in Huntsville, Alabama

3D printing is a form of additive manufacturing that can reduce costs and enhance capabilities. One benefit of 3D printing in rocket fabrication is that it can reduce the number of separate components that need to be welded together. 

NASA has also built and tested a 3D-printed rocket engine nozzle made of aluminum. The nozzle is lighter than conventional nozzles and could enable deep space flights that can carry more payloads.

In fall 2023, NASA successfully tested the Rotating Detonation Rocket Engine (RDRE) at its Marshall Space Flight Center in Huntsville, Alabama. The RDRE is a 3D-printed propulsion system. The 251-second “hot fire test” generated more than 5,800 pounds of thrust

The RDRE is made up of two coaxial cylinders with a gap in between. Fuel and oxidizer flow into the gap, and detonation travels around the annulus, burning the mixture. The products exit the nozzle axially, creating thrust.

A 3D-printed rocket engine is a rocket engine that’s been manufactured using 3D printing technology. The process involves creating a 3D model of the engine using computer-aided design (CAD) software, and then converting it into a printable file format

3D-printed rockets are more fuel efficient, lighter, and can be built faster than traditional rockets. In 2017, a 3D-printed rocket engine successfully launched a rocket to space.

3D-printed rockets are made of lightweight metal alloys, such as aluminum, titanium, copper, nickel, and chromium. These alloys are fused together using additive manufacturing methods, like direct energy deposition and selective laser sintering

For example, the engine combustion chamber is printed using Inconel, an alloy of nickel and chromium. Inconel is printed using a process of direct metal laser sintering. 

Spacecraft companies use laser-based metal 3D printing technologies, like Selective Laser Melting (SLM), to produce rocket engine parts. These parts include combustion chambers, nozzles, injectors, pumps, and valves.

The aerospace industry uses a variety of 3D printing technologies, including: 

• Selective laser sintering (SLS) Uses a laser to create objects from plastic powder. SLS is good for producing parts with complex geometries at high resolutions. It’s commonly used in aerospace for small-batch production of flexible airflow components and heat-resistant parts. 
• Selective laser melting (SLM) The preferred metal 3D printing process for aircraft on Earth. In this procedure, the metal sample is injected from a hopper onto a construction plate, and each deposited layer is about the thickness of a single strand of human hair. 
• Material jetting A process in which tiny droplets of liquid material are selectively deposited onto a build plate and cured by heat or UV light. 
• Multi Jet Fusion (MJF) Can create highly accurate, complex industrial parts more efficiently and potentially more cost-effectively than other industrial 3D printing processes. 

Other 3D printing technologies used in aerospace include: DMLS, EBM, SLA, DLP, FDM.

NASA has developed and tested a 3D-printed aluminum rocket engine nozzle that is lighter than conventional nozzles. The nozzle, called RAMFIRE, can withstand internal temperatures of up to 6,000°F (3,315°C)

The nozzle is made of a weldable type of aluminum, which is ideal for spacecraft because it has a lower density and can be used for lightweight, high-strength components. The nozzle successfully completed 22 start tests and fired for nearly 10 minutes. 

The new technology could enable deep space missions to carry heavier payloads

A rotating detonation rocket engine(RDRE) is a new propulsion system developed by NASA. It uses a continuous detonation wave to burn fuel and oxidizer instead of a deflagration flame

RDRE works by rapidly rotating and detonating a mixture of fuel and oxidizer in a continuous combustion cycle. This generates high-pressure and high-temperature gases that provide thrust

NASA tested its first full-scale RDRE on January 25, 2023, and it produced 4,000 pounds-force of thrust. NASA plans to create a 10,000-pound-force thrust unit as the next research step. 

RDRE could provide high thrust at much greater efficiency compared to today’s rocket engines. Detonation engines have a considerably higher theoretical level of efficiency than combustion engines, perhaps as much as 25%. 

The RDRE program at AFRL is developing more efficient, compact, and stable combustor designs for Liquid Rocket Engines (LREs)

NASA has been testing 3D-printed rockets and rocket nozzles. In March 2023, the Terran 1 rocket, developed by Relativity Space, became the first rocket with 3D-printed parts to reach space. The Terran 1 is 100 feet tall and 7.5 feet wide, and 85% of the methane-fueled rocket is 3D printed

NASA has also tested a 3D-printed Rotating Detonation Rocket Engine combustor at its Marshall Space Flight Center in Huntsville, Alabama. The combustor was fired for 251 seconds and achieved more than 5,800 pounds of thrust. NASA has also tested a new experimental rocket nozzle using 3D printing techniques. 

NASA is also developing 3D print head technology to enable large-scale additive construction using in-situ resources. This innovation could reduce the need to transport materials from Earth and allow for sustainable habitat development on the Moon or Mars

NASA is using 3D printing for a number of purposes, including: 

• Reducing costs and production times 3D-printed rocket engine parts can reduce manufacturing costs and production times. 
• Creating high-temperature materials NASA has developed a 3D-printable superalloy that could lead to stronger, more durable parts for airplanes and spacecraft. 
• Creating large-scale engines NASA uses 3D printing techniques to create large-scale engines for space rockets in its Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project. 
• Creating replacement parts 3D printing could help astronauts create replacement parts for repairs, custom equipment for scientific experiments, and even things like food or buildings. 
• Creating low mass, high-precision parts In 2020, NASA launched the Perseverance Rover to Mars with eleven 3D printed metal parts and tools. These allowed for low mass and high-precision targeting not achievable with conventional manufacturing. 
• Printing food NASA is experimenting with 3D printing food during deep space missions. 
• Printing chainmail NASA is experimenting with 3D printing chainmail that can be printed in metal to protect astronauts and spacecraft from harmful impacts.

3D printing has the potential to revolutionize manufacturing in space, making it more sustainable, cost efficient, and flexible

Here are some possible future applications of 3D printing in space exploration: 

• Large-scale 3D printers These printers could produce modules for space stations or habitats on other planets. 
• Space-proof materials 3D printing can produce large-scale, lightweight, flexible objects made of space-proof materials. 
• On-demand printing Engineers can print objects on demand, with complex designs costing no more than simple ones. 
• Emergency response 3D printing could help with emergency response and deep space exploration.

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