Eplus3D and LEAP 71, a company specializing in computational engineering, have jointly developed the world’s largest 3D-printed rocket engine from a single piece. With an output of 200 kN and a height of over 1.3 meters, the engine will be unveiled at Formnext 2024 in Frankfurt.
The engine was designed by LEAP 71 using the Noyron Computational Engineering Model. This AI-based system enables the design of highly complex machines without the use of traditional CAD software. Production was carried out on an EP-M650-1600 printer from Eplus3D, which uses six 500-watt lasers and offers a build size of 650 × 650 × 1600 mm. Production took 354 hours and was completed in one continuous process.
The design combines all the major components of a rocket engine, including the combustion chamber, nozzle, cooling channels and manifold elements, into a single, integrated structure. This design eliminates the need for multiple components that must be traditionally assembled and sealed. The engine is made from the aluminum alloy AlSi10Mg, which, despite its excellent properties for lightweight applications, is a challenge to process due to its high reactivity.
The engine uses a two-stage cooling strategy: liquid oxygen provides regenerative cooling for the main combustion chamber, while kerosene cools the upper nozzle. This configuration improves thermal efficiency and increases the stability of the engine during operation.
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