Advancing Rocket Propulsion Manufacturing with 3D Dynamic Material Deposition Process

In this presentation, we investigate the implementation of the High-Speed Directed Energy Deposition with Laser Beam (DED-LB) process, specifically 3D Dynamic Material Deposition (3DMD) technique, within the production chain of rocket combustion and thrust chambers. This marks a significant advancement in hybrid production capabilities.
The integration of the 3DMD process offers a paradigm shift in hybrid production capabilities. Notably, it facilitates the application of multimaterial coatings, such as depositing Inconel on copper alloy, obviating the necessity for an interface material. This breakthrough not only enhances material compatibility but also streamlines the manufacturing process by eliminating intermediary steps and reducing material waste.
Furthermore, the potential elimination of heat treatments, attributable to the 3DMD process, significantly shortens lead times in comparison to traditional manufacturing methods. The inherent high productivity and efficiency of this approach contribute to faster production cycles while maintaining high precision and minimizing material wastage. Finally, the 3DMD process generates low distortion rates, thereby ensuring the integrity and dimensional accuracy of manufactured components. This characteristic holds profound implications for the reliability and performance of rocket propulsion systems.
Beyond its application in the hybrid manufacturing of rocket combustion and thrust chambers, the versatility of the 3DMD process extends to the realization of expansion nozzles and nozzles with integrated cooling channels, as well as repair applications and the direct fabrication of parts, offering viable alternatives to conventional manufacturing techniques.
In summary, this presentation illuminates the transformative potential of integrating High-Speed DED-LB processes, with 3DMD technology, into the aerospace industry, particularly within the field of rocket propulsion system manufacturing. The synergistic combination of material compatibility, accelerated production timelines, minimal distortion, and diverse applications underscores the profound impact of this advancement on the space technology landscape.