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Based on hot-fire tests of an Expander-cycle Integrated Demonstrator (ETID) that proved the technology and methods last year, ESA, ArianeGroup and DLR German Aerospace Center have built and hot-fire tested a fully additively-manufactured thrust chamber. See ETID fact sheet.
This first test lasted 30 seconds and was carried out on 26 May 2020 at the DLR German Aerospace Center’s Lampoldshausen testing facility. Additional tests are planned next week. The data from this test campaign will be collected and analysed.
This fully 3D-printed thrust chamber is built in just three parts and could power the upper stages of future rockets.
Additive layer manufacturing also known as 3D-printing, allows more complex designs for higher performance, vastly reduces the number of parts in this case from hundreds to three, and speeds up production time. This reduces costs and significantly improves the competitiveness of liquid propulsion engines for European launch vehicles.
This fullscale chamber has a 3D-printed copper liner with integrated cooling channels and a high-strength jacket built on via cold-gas spraying. Its manifold and single-piece injector head are also 3D-printed.
The production and test of these parts has been performed within ESA's Future Launchers Preparatory Programme.