Close Menu
AM ChronicleAM Chronicle
  • Content
    • News
    • Insights
    • Case Studies
    • AM Infocast
  • Focus Regions
    • India
    • Asia Pacific
    • Middle East
    • North America
    • Europe
  • Industries
    • Automotive
    • Aerospace
    • Defence
    • Energy
    • Construction
    • Healthcare
    • Tooling
    • Engineering
  • Training
  • Magazine
    • Digital Issues
    • Print Subscription
  • Events
Facebook Instagram YouTube LinkedIn
  • About us
  • Media Kit
  • Contact us
Facebook Instagram YouTube LinkedIn
AM ChronicleAM Chronicle
  • Content
    1. News
    2. Insights
    3. Case Studies
    4. AM Infocast
    5. View All
    3D printing ceramics with Admaflex DLP technology. Photo via Admatec.

    Admatec and Formatec Re-emerge Under New Ownership and Names

    July 3, 2025
    Sailors aboard the Virginia-class attack submarine USS Texas prepare to depart Portsmouth Naval Shipyard after critical repairs and system upgrades. As the Navy works to enhance fleet readiness and extend the service life of submarines like Texas, APL researchers are partnering with the Naval Sea Systems Command to advance additive manufacturing processes — such as laser powder bed fusion — to deliver consistent, mission-ready components and reduce logistics delays across the fleet.

    Johns Hopkins APL, Navy Team up to Advance Additive Manufacturing for Critical Missions

    June 28, 2025
    Freemelt receives order for Freemelt ONE from a German industrial company, Credits: Freemelt

    Freemelt receives order for Freemelt ONE from a German industrial company

    June 25, 2025
    Sandvik and Additive Industries Announce Strategic Partnership for Direct Powder Delivery, Credits: Sandvik

    Sandvik and Additive Industries Announce Strategic Partnership for Direct Powder Delivery

    June 25, 2025
    LACS equipment set-up to add a coating to repair a panel aircraft wing

    Laser-assisted cold spray: a new generation of innovative manufacturing technology

    July 3, 2025
    Oerlikon Reaches 25,000 3D-Printed Suppressors Milestone, Advancing Next Generation Defense Applications, Credits: Oerlikon

    Oerlikon Reaches 25,000 3D-Printed Suppressors Milestone, Advancing Next Generation Defense Applications

    June 24, 2025
    ArianeGroup and Nikon SLM Solutions Join Forces to Advance Ultra-Large-Scale Additive Manufacturing for Space Applications

    ArianeGroup and Nikon SLM Solutions Join Forces to Advance Ultra-Large-Scale Additive Manufacturing for Space Applications

    June 21, 2025
    HBD Advances in Metal 3D Printing for Customized Orthopedic Implants

    HBD Advances in Metal 3D Printing for Customized Orthopedic Implants

    June 13, 2025
    Formlabs fuse 1+

    How Imaginarium Helped Kaash Studio Scale with the Right 3D Printing Technology

    April 12, 2025
    The Formlabs Fuse 1+ 30W

    Kaash Studio Optimized Service Bureau Operations with Formlabs 3D Printers- Case Study

    January 30, 2025
    Namthaja Unveils Worlds First 3D Printed Marine Gangway

    Worlds First 3D Printed Marine Gangway unveiled by Namthaja

    August 8, 2024
    RusselSmith Material Performance Improvement Whitepaper

    RusselSmith Whitepaper : Improving Material Performance with Microstructural Refinement

    May 9, 2024
    Sustainable Production of Metal Powder for Additive Manufacturing

    Sustainable Production of Metal Powder for Additive Manufacturing with Bruce Bradshaw

    February 15, 2024
    Meeting Evolving Customer Demands in the Additive Manufacturing Industry with Tyler Reid

    Meeting Evolving Customer Demands in the Additive Manufacturing Industry with Tyler Reid

    February 9, 2024
    Innovation is at the heart of AMUG with Diana Kalisz

    Innovation is at the heart of AMUG with Diana Kalisz

    March 7, 2023
    3D Printing Workshops at AMUG with Edward Graham

    3D Printing Workshops at AMUG with Edward Graham

    March 7, 2023
    LACS equipment set-up to add a coating to repair a panel aircraft wing

    Laser-assisted cold spray: a new generation of innovative manufacturing technology

    July 3, 2025
    3D printing ceramics with Admaflex DLP technology. Photo via Admatec.

    Admatec and Formatec Re-emerge Under New Ownership and Names

    July 3, 2025
    Sailors aboard the Virginia-class attack submarine USS Texas prepare to depart Portsmouth Naval Shipyard after critical repairs and system upgrades. As the Navy works to enhance fleet readiness and extend the service life of submarines like Texas, APL researchers are partnering with the Naval Sea Systems Command to advance additive manufacturing processes — such as laser powder bed fusion — to deliver consistent, mission-ready components and reduce logistics delays across the fleet.

    Johns Hopkins APL, Navy Team up to Advance Additive Manufacturing for Critical Missions

    June 28, 2025
    Platinum Guild International Unveils Inaugural 3D-Printed Platinum Collection, Credits: Platinum Guild International

    Platinum Guild International Unveils Inaugural 3D-Printed Platinum Collection

    June 28, 2025
  • Focus Regions
    • India
    • Asia Pacific
    • Middle East
    • North America
    • Europe
  • Industries
    • Automotive
    • Aerospace
    • Defence
    • Energy
    • Construction
    • Healthcare
    • Tooling
    • Engineering
  • Training
  • Magazine
    • Digital Issues
    • Print Subscription
  • Events
Subscribe
AM ChronicleAM Chronicle
Home » News

AFRL researchers pave the way to a new way of manufacturing rocket engines

News Press Release By AM Chronicle EditorMay 6, 20243 Mins Read
rocket lab1
The Air Force Research Laboratory, or AFRL, Rocket Propulsion Division, recently designed, printed, built and hot fired a first-ever, single-block rocket-engine thrust chamber additively manufactured using a process called laser powder directed energy deposition, or DED. DED is an additive manufacturing process in which the device injects metal powder into focused beams of high-power laser in highly controlled atmospheric conditions. The Hotfire of the thrust chamber is shown in the Experimental Cell 1 (EC-1) at the AFRL Rocket Lab. (Air Force photograph)
LinkedIn Twitter Facebook WhatsApp Pinterest Email Copy Link

AFRL researchers pave the way to a new way of manufacturing rocket engines

The Air Force Research Laboratory, or AFRL, Rocket Propulsion Division, recently designed, printed, built  and hot fired a first-ever, single-block rocket-engine thrust chamber additively manufactured using a process called laser powder directed energy deposition, or DED.

“AFRL’s investments in early advanced manufacturing techniques enable us to exploit corners of the design space for rocket engines and enable faster design turnover cycles from a concept in a whiteboard to test & evaluation in the field,” said Dr. Javier Urzay, chief Combustion Devices Branch.

DED is an additive manufacturing process in which the device injects metal powder into focused beams of high-power laser in highly controlled atmospheric conditions. “It provides the largest build box volume for thruster hardware to date, capable of printing seven-foot-tall parts. This build box volume is much larger than that obtainable with techniques like the laser powder bed fusion, or LPBF, process. In addition, DED enables an order of magnitude less investment in powder and less material waste. Engineers can also realize alloy blending and transitions in real time for multi-alloy builds to exploit the strength, weight and performance gains of next-generation superalloys,” said Urzay.

Edgar Felix Lead Investigator front and Isaiah Jaramillo Mechanical Specialist work on the first ever
Edgar Felix, Lead Investigator, front and Isaiah Jaramillo, Mechanical Specialist, work on the first-ever, single-block rocket-engine thrust chamber additively manufactured using a process called laser powder directed energy deposition, or DED. DED is an additive manufacturing process in which the device injects metal powder into focused beams of high-power laser in highly controlled atmospheric conditions. (Air Force photograph)

“These unique capabilities allow us to tackle complex engine designs requiring fewer iterations and leveraging shape optimization, lightweight materials, advanced metal alloys and composites, and rapid manufacturing,” Urzay said.

The AFRL Rocket Propulsion Division, a component of the Aerospace Systems Directorate, is working alongside the U.S. space industry to embed these advanced additive manufacturing processes into robust digital engineering environments.

Additive manufacturing works closely with the transition from traditional ways of manufacturing rocket engine hardware to automated manufacturing processes fed by digital environments involving artificial intelligence, machine learning, digital twins, 3D volumetric scanners and computer aided design, or CAD.

The multifaceted nature of the digital environment is necessary to manage the printers that produce lightweight thrust chambers, manifolds, injectors, pressure vessels, valves and turbomachinery blades with 3D shapes and internal features that are not easily achievable using traditional methods.

“While additive manufacturing offers many opportunities for accelerated production at lower costs, several challenges remain in the way of making this technology widely adopted by the rocket-propulsion industry and government laboratories,” said Edgar Felix, aerospace engineer at the Combustion Devices Branch.

AFRL is addressing the unique challenges of producing materials that can withstand the harsh environments in which rocket engines must perform.

AFRL experts combine decades of rocket combustion chamber experience with insights into the challenges and opportunities of these new manufacturing techniques and maintain close collaborations with several external organizations that bring unique skills to the table.

“This latest breakthrough in additive manufacturing for rocket engines in our branch is one in a series that has been made possible only by forging long-lasting relationships across multiple industrial partners and government organizations, including the AFRL Materials and Manufacturing Directorate and NASA Marshall Space Flight Center,” Urzay said. “Their work is extremely valuable for the nation, and together we are an unstoppable team.”

The AFRL Rocket Propulsion Division continues to work on novel techniques for additive manufacturing with the goal of surging capacity in both liquid rocket engines and solid rocket motors.

Original Source

3d printing additive manufacturing AFRL
AM Chronicle Editor

NAMIC GLOBAL AM SUMMIT 2025
LATEST FROM AM
LACS equipment set-up to add a coating to repair a panel aircraft wing Insights

Laser-assisted cold spray: a new generation of innovative manufacturing technology

July 3, 20259 Mins Read
3D printing ceramics with Admaflex DLP technology. Photo via Admatec. News

Admatec and Formatec Re-emerge Under New Ownership and Names

July 3, 20253 Mins Read
Sailors aboard the Virginia-class attack submarine USS Texas prepare to depart Portsmouth Naval Shipyard after critical repairs and system upgrades. As the Navy works to enhance fleet readiness and extend the service life of submarines like Texas, APL researchers are partnering with the Naval Sea Systems Command to advance additive manufacturing processes — such as laser powder bed fusion — to deliver consistent, mission-ready components and reduce logistics delays across the fleet. News

Johns Hopkins APL, Navy Team up to Advance Additive Manufacturing for Critical Missions

June 28, 20255 Mins Read

CONNECT WITH US

  • 126 A, Dhuruwadi, A. V. Nagvekar Marg, Prabhadevi, Mumbai 400025
  • [email protected]
  • +91 022 24306319
Facebook Instagram YouTube LinkedIn

Newsletter

Subscribe to the AM Chronicle mailer to receive latest tech updates and insights from global industry experts.

SUBSCRIBE NOW

Quick Links

  • News
  • Insights
  • Case Studies
  • AM Training
  • AM Infocast
  • AM Magazine
  • Events

Media

  • Advertise with us
  • Sponsored Articles
  • Media Kit

Events

  • AM Conclave 2025
    24-25 September 2025 | ADNEC, Abu Dhabi
  • AMTECH 2025
    3-4 December 2025 | KTPO, Whitefield, Bengaluru
CNT Expositions & Services LLP
© 2025 CNT Expositions & Services LLP.
  • Privacy Policy
  • Cookie Policy

Type above and press Enter to search. Press Esc to cancel.



0 / 75