3D Metal Printed Aerospace Parts – Sciaky in Space and on the Moon
Metal 3D printing continues to emerge as a highly effective manufacturing method for specialized aerospace parts. As a case in point, take a look at these 3D printed jet engine nozzles produced by Sciaky for Intuitive Machines – officially the first critical 3D printed metal part on the moon.
We manufactured these components for Intuitive Machines’ IM-1 mission to the Moon using our innovative electron beam additive manufacturing (EBAM) process. The mission flew to success in February of 2024 – marking the first time America had landed on the moon since the Apollo 17 mission in 1972. Over half a century later, with increasing investment in both military and commercial spaceflight, 3D metal printing is now creating new possibilities as humanity reaches further toward the stars.
Metal Printing in Action: Jet Engine Nozzles and Other Critical Aerospace Parts
Intuitive Machines’ upper engine nozzle is a complex component requiring advanced materials, enhanced manufacturing flexibility, and high-precision results. It was one of myriad critical parts required for mission success and safety, functioning as the main source of thrust during vehicle descent.
We printed three parts in total – two for testing, one for installation. The application called for a high-cost, difficult-to-deposit refractory alloy. Our efficient EBAM process was ideal for minimizing material waste while facilitating rapid production.
The end result: a cost-effective manufacturing process requiring only 16 hours to create fully functional engine nozzles that helped carry the spacecraft more than 230,000 miles to the lunar surface.
The Only Company with with 3D Printed Titanium Parts for Land, Sea, Air, and Space
While there were inevitable challenges, Intuitive Machines’ IM-1 Mission was ultimately a huge success. The mission is part of NASA’s larger Commercial Lunar Payload Services (CLPS) initiative, which is currently exploring new possibilities in future manned missions.
No doubt metal printing will play an even bigger role in the future of aerospace as humanity steps foot on the moon once again and potentially sets sight on Mars.
Precision Metal Printed Aerospace Parts and Components at Sciaky
Aerospace parts typically require a combination of high strength, light weight, and exceptional design complexity. High-precision tolerances and repeatability are crucial concerns, requiring virtually perfect form and fitment to ensure compatibility within extremely sensitive aerospace systems. Finally, there are the material costs to consider. Whether it’s titanium, special nickel alloys, or other uniquely formulated high-cost alloys, material waste must be minimized in order to keep costs in check.
Sciaky’s EBAM metal printing services excel in all of these requirements. The process is relatively quick, efficient, and economical, while being readily compatible with high-precision tolerances and exceptionally complex geometries. Some of the common aerospace product applications include:
- Aerospace structural elements
- Airframe components
- Jet and propulsion systems
- Specialized aerospace hardware
- Turbine blades and components
See our Press Release on Metal Printing for Intuitive Machines for a closer look at the above project. Check out our Lockheed Martin Space Systems case study for another look at aerospace titanium 3D printing in action.
Innovation in Additive Manufacturing for Tomorrow’s Aerospace Industry
Founded in 1939, Sciaky is backed by more than eight decades of innovation and manufacturing excellence in the cutting-edge aerospace industry and beyond. We’ve continuously embraced the rise of 3D metal printing across industries through the refinement of our innovative Electron Beam Additive Manufacturing (EBAM) processes.
