Robotic Deposition Technology (RDT-ACO )

Aerojet Rocketdyne (AR), in a partnership with NASA Marshall Space Flight Center is providing revolutionary capabilities for NASA's Exploration goal of developing advanced manufactured components for Lunar and Mars missions as well as for NASA's Commerce goal of growing the US's Space economy. The matured products and technologies that have been developed from this ACO will mutually benefit both commercial and government with a common goal of advancing novel Additive Manufacturing (AM) technologies and infusing them into various liquid rocket engine applications for cost savings and performance improvements. The ACO has met the objective to demonstrate design, manufacture, and test of an innovative and lightweight Thrust Chamber Assembly (TCA) that will incorporate automated robotic deposition AM technologies: Cold Spray Deposition (CSD) and Laser Wire Direct Closeout (LWDC). The ACO has met the goal to evolve these processes using weight-optimized materials to validate operability, performance, and reusability of lander-size TCA through hot-fire testing.

The incorporation of automated robotic deposition additive manufacturing technologies to make a TCA is considered unique and innovative because it is a novel approach to fabricate the complex TCA components – thrust chamber liner, channel closeout, and structural jacket. This new AM solution gives three major benefits; 1) Cost Efficient with potentially large recurring cost savings per thrust chamber – it is expected to reduce the cost (up to 50%) by eliminating or simplifying a number of traditional manufacturing processes such as long lead item forging, electroplating, use of precious metals, and braze foil application. 2) Scalable for larger thrust level TCA – unlike Powder Bed Fusion (PBF) AM technology where there is a limit in "printable" size due to the build envelope constraint , these AM technologies are processed in an open environment with robotic system and no limit in printable size. Potential insertion opportunity includes the current NASA's Space Launch System propulsion systems as well as Lunar and Mars Lander and Surface Propulsion system. 3) Extensible to add new manufacturing capabilities to the US Space market – it opens up the vertical integration capability for many small-to-medium commercial companies in regards to being able to manufacture with limited infrastructure. This approach allows for a broader competitive market space for liquid rocket production in the US.

This is early/mid-stage (TRL 5) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

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