Utilization of Metal Additive Manufacturing for Sounding Rocket Flight Structures

The proposed development is a maturation effort in support of qualifying metal additive manufacturing (AM) techniques for use on flight projects. The Sounding Rocket Program Office (SRPO) as well as other project offices have determined the development and utilization of additive manufacturing techniques for payload and vehicle components as one of their key technology needs. The greatest advantage of additive manufacturing is that it allows for greater freedom to dictate part geometry, thus allowing for weight-efficient designs that are optimized for maximum stiffness or maximum strength. For payload structures and components that have a weight-efficient design, the overall system weight is reduced, and science time is increased. Additionally, the greater freedom for part geometry can reduce part counts and allow the engineer to integrate what otherwise would have been a multi-part assembly into a single integrated structure. An example of this is a “spider” bracket, which is sometimes used to position a star tracker in the center of a sounding rocket telescope. An integrated part maximizes stiffness and reduces assembly misalignment. Utilization of AM in aerospace applications has been on the rise and recently published NASA technical standards on AM mark a significant shift in acceptance of the technology. Notably, MSFC has dedicated significant investment and research in AM for spacecraft applications. This development aims to 1) investigate the utility of metal AM structural components through research, design, analysis, and test; and 2) develop and bolster design competencies for AM applications and generative design concepts. Ultimately, the utilization of these technologies is intended for structural use on sounding rocket payloads as well as other suborbital flight applications.

The ability to utilize complex geometries through AM allows for several benefits. Past design efforts have shown that the ACS manifold mass can be reduced by 41.8% and similar opportunities likely exist elsewhere. Additionally, the more efficient roll control nozzle geometry has improved the nozzle’s impulse, although analysis has not yet been determined of the performance increase. The ability to incorporate multiple pieces into a single part has demonstrated improvements to stiffness and the reduction of misalignments in alignment critical assemblies. Another potential benefit for utilizing AM processes is that it increases the ability to produce multiple piece parts in a single setting, although limited on the build volume of the printer. This will reduce the cost of setup time used in traditional fabrication methods.

This is early/mid-stage (TRL 4) — 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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