The Noyron TKL-200, a aluminum rocket engine developed through the collaboration of LEAP 71 and Eplus3D, will be a key highlight at AMTECH 2024, by Lodestar 3D. This high-performance rocket engine, printed entirely from AlSi10Mg alloy, stands as a testament to the revolutionary potential of additive manufacturing and computational design in aerospace engineering. The event will take place on December 11-12, 2024, at the KTPO Trade Centre, Bengaluru, offering visitors a chance to witness this engineering marvel up close.
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Designed by Advanced Computational AI
What sets the TKL-200 apart is its design methodology. Created autonomously by the Noyron RP Large Computational Engineering Model, the rocket engine exemplifies how artificial intelligence can redefine traditional engineering processes. The computational design process eliminates the need for conventional CAD tools, producing a fully functional engine design in under three weeks. Each iteration of Noyron RP takes just 30 minutes, showcasing its unparalleled efficiency in design-to-production cycles.
Manufactured with Metal 3D Printing Technology
The TKL-200 was produced on the Eplus3D EP-M650-1600, a Metal Powder Bed Fusion (MPBF) printer equipped with six 500W lasers. This industrial-grade system offers a substantial build volume of 650x650x1600mm, enabling the production of large components such as the TKL-200, which stands at over 1.3 meters tall (4 feet 3 inches). The engine’s intricate design and impressive build size fully utilize the printer’s capabilities, pushing the boundaries of what is achievable with metal 3D printing.
The printing process, completed in just 354 hours over two weeks, was executed seamlessly without interruptions. Eplus3D maintained strict quality standards, including an oxygen level below 100ppm in the process chamber, ensuring the engine’s superior surface finish. Furthermore, the layer height was meticulously set at 60µm to minimize surface roughness in the cooling channels, critical for efficient heat management during operation.
High-Performance Specifications
The Noyron TKL-200 delivers an astounding 200 kN (45,000 lbf) of thrust, placing it on the higher end of engines designed for small launcher first stages. With a chamber pressure of 100 bar, the engine is capable of burning over 70 kilograms of propellant per second, using cryogenic liquid oxygen and kerosene as propellants. Its advanced design incorporates regenerative cooling via helically arranged channels, ensuring effective heat dissipation and structural integrity under extreme conditions.
The use of AlSi10Mg, a high-performance aluminum alloy, provides the engine with an exceptional thrust-to-weight ratio, offering lightweight solutions for aerospace applications. However, aluminum’s low melting point poses significant challenges, which the Noyron RP computational AI overcomes by optimizing cooling strategies and wall thicknesses. The engine employs a two-stage cooling system, with cryogenic liquid oxygen cooling the combustion chamber and kerosene cooling the upper nozzle.
Functionally Integrated Design
Thanks to advanced computational engineering, the TKL-200 integrates multiple components into just two main parts, including the combustion chamber, cooling channels, manifolds, injectors, ignition system, and structural features. This level of integration reduces assembly complexity, shortens production timelines, and enhances reliability, setting a new standard for rocket engine manufacturing.
One of the most significant ability demonstrated by the TKL-200 is the ability to reduce design-produce-test-redesign cycles from months or years to mere weeks. This rapid iteration capability is made possible by combining Noyron’s computational AI with Eplus3D’s industrial-grade 3D printing technology. The engine’s design and manufacturing processes represent a paradigm shift for aerospace engineering, enabling faster innovation and deployment of propulsion systems.
A Highlight of AMTECH 2024
At AMTECH 2024, attendees will have the opportunity to witness the Noyron TKL-200 rocket engine and explore its innovative features firsthand. Lodestar 3D will showcase this cutting-edge technology, emphasizing its role in advancing the aerospace industry and demonstrating the transformative potential of additive manufacturing and computational AI.
This showcase will not only inspire industry professionals but also provide a glimpse into the future of aerospace design and manufacturing.
About Lodestar3D
We at Lodestar3D, are passionate about bring the latest and most cutting edge additive manufacturing and reverse engineering solutions to India. Our expertise spans across all kinds of technologies like SLA/SLS/DMLS/EBM/Sand/Wax & Ceramic 3D printing. We bring the complete additive manufacturing eco-system integrating hardware, software and consumables innovated across the world and optimized for India.
For more information, please visit https://lodestar3d.com/
About Eplus3D
Eplus3D is a professional additive manufacturing equipment manufacturer and application solution provider, especially in the field of metal 3D printers. Since founding the first PBF machine in China in 1993, Eplus3D is engaged in research and development of industrial-grade Additive Manufacturing systems and application technologies using MPBF™ (Metal Powder Bed Fusion) and PPBF™ (Polymer Powder Bed Fusion) 3D printing technology.
Eplus3D has four facilities in Beijing, Hangzhou, Stuttgart and Houston, with an annual scientific research investment of more than 20% of the revenue with comprehensive invention patents, utility model patents, software copyrights as well as appearance patents. It has made remarkable achievements in the design, process, software, materials and post-processing development for additive manufacturing.
For more information, please visit https://eplus3d.com
About LEAP 71
Our mission at LEAP 71 is to radically transform engineering for the real world. While information technology is continuing to advance at Moore’s Law of exponential growth, much of our physical world has changed surprisingly little in the past decades. We are pioneers in the new field of Computational Engineering, where parts, structures, and entire machines are designed using software models, which translate human engineering knowledge into algorithms.
For more information, please visit https://leap71.com/
About AMTECH
AMTECH stands as the foremost business networking platform in India dedicated to Additive Manufacturing Technology. Immerse yourself in the dynamic ecosystem of 3D Printing and Additive Manufacturing Technology. Explore state-of-the-art exhibits, gain insights from conferences led by experts, and engage with industry professionals. Make informed decisions about integrating Additive Manufacturing into your Manufacturing Process through meaningful networking opportunities.
To know more visit https://amtechexpo.in/
