In a recent interview, Principal Engineer Paul Gradl from NASA discussed the significant impact of additive manufacturing (AM) on the development of new rocket technology. The use of metal AM in rocket engine development and production has resulted in a substantial reduction in prototyping and testing time, allowing for rapid iterations. This has enabled the team to produce prototypes within a week to a few months and promptly put them to the test, ultimately leading to more efficient designs. Throughout his two-decade tenure, Gradl has played a crucial role in the development of liquid rocket engine components, including combustion devices and turbomachinery.
NASA has been at the forefront of adopting additive manufacturing technologies, initially utilizing polymers for prototypes nearly 25 years ago. Despite initial challenges with metal prints, the technology has gradually improved, enabling the production of reliable components. Gradl also highlighted the development of advanced materials specifically designed for aerospace applications, such as GRCop-42, an alloy crucial for rocket engine combustion chambers, which has shown significant improvements in wall temperatures. This material is now finding applications in other industries such as the energy sector.
NASA’s commitment to developing and utilizing advanced materials has not only benefitted the space sector but has also contributed to technological advancements in other high-performance industries. An example of this is the Rotating Detonation Engine (RDE), a significant advancement in rocket engine efficiency, made possible through AM and advanced materials.
Looking towards the future, Gradl emphasised the importance of improving the speed of AM processes without sacrificing material quality. He stressed the need for a systems approach in AM, integrating all aspects of the additive lifecycle, and encouraged closer collaboration between machine manufacturers and post-processing vendors.
Ultimately, the conversation with Gradl highlighted the diverse and far-reaching impact of additive manufacturing in revolutionizing various fields, also indicating its potential to revolutionize various sectors.