Swiss scholars invent speedier, economical 3D printer for manufacturing rocket components

In a groundbreaking development, a team of six bachelor students from Switzerland have created a new 3D printing machine that is set to transform the aerospace industry. The innovative device, named RAPTURE, was designed and built in just nine months at the Fraunhofer Institute for Laser Technology (ILT).

The 3D printer utilizes a rotating laser powder bed fusion (LPBF) system, allowing it to print cylindrical metal parts faster than conventional systems. This speedy production is achieved by the printer's continuous operation, as it rotates the printing platform to deposit and fuse powder, reducing production time for cylindrical components by more than two-thirds.

One of the most significant advancements of this new technology is its ability to simultaneously process multiple metals in a single operation. For instance, it can print rocket nozzles with a copper core and a nickel-alloy exterior in one seamless step, a capability current 3D printers can't achieve without multiple printing stages or complex post-processing.

Michael Robert Tucker, a lecturer at the Department of Mechanical and Process Engineering, commented on the process's potential impact on the aerospace industry. He noted that the technology could revolutionize the production of components such as rocket nozzles, rotating engines, and many others.

The university has reportedly filed a patent for the technology, citing its potential in aerospace, automotive, and energy sectors. The student-led project was designed to help ARIS build bi-liquid-fueled rocket nozzles capable of surviving spaceflight conditions.

The machine's gas flow mechanism has been identified as crucial to the quality of the printed parts. Its rotating powder delivery and gas flow system prevent oxidation during the printing process, ensuring a cleaner build environment and higher part integrity.

The RAPTURE 3D printer has already produced turbine stators up to 7.8 inches in diameter. The team is now working to scale up the process and partner with industry players. They aim to reach the Kármán Line in the coming years, contributing significantly to the advancement of space exploration technology.

The study detailing the development of this innovative 3D printer has been published in the prestigious journal CIRP Annals. This breakthrough is yet another example of how young minds can push the boundaries of technology and shape the future.