How I 3D Printed a Metal Aerospike Rocket at Home

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Tree Killer: @Ididathing

Virtual Foundry

#rocket #aerospike #3dprinting

Integza

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Im so bored that im watching a video from a guy on youtube about 3d printing metal

Ididathing

I don't blame that aerospike tip for melting. I'd melt in the presence of the Tomato Lord as well.

PlasmaChannel

There's no need to use special "sintering carbon", any activated carbon should work (sold for water filters or fish-tank filters). Or even a carbon source that will become activated carbon on heating, like paper or wood, though that would require a ceramic tile to lay on top of the crucible to limit air getting in. Putting a tile on top of the crucible to limit airflow is probably a good idea regardless.

Nuovoswiss

I love how he gives away 3D printers. He is supporting and inspiring to invent. Hats Off!

bishalgolder

"It melted the steel!" Yeah, this is why aerospikes are generally a bad idea... (actually one of the biggest reasons they aren't really used). You could try a de Laval though!

commandershepard

The nozzle didnt melt, it burnt. The oxygen rich exhaust cobined with the heat is oxidicing iron/steel increadibly fast

StorcheiLP

Nice work. Having worked in the rocket engine business for a few years I have a few suggestions to make your nozzle last longer. I suspect given how long the flame out the back is you are running significantly oxidizer rich combustion, and that is burning out the steel nozzle the same way an oxy acetylene torch would cut through steel. Fun fact about oxy acetylene cutting, once the cut is initiated you can cut the fuel flow and finish the cut. I'd try running less oxygen if you are going to stick with the steel material you are currently using. Second suggestion. Material change. The site you got your materials from have an inconel 718 filament listed. I don't know if your overn will do their sintering profile, but of the materials I saw at a quick glance that inco 718 material has the best shot at resisting oxidation in a nozzle application. A monel or mondaloy would be better, but I doubt they will be making those into filaments anytime soon. Third suggestion. The metal filament company has an aluminum 6061 filament listed. You might try printing your fuel grain out of that and not sintering it. Aluminum will be a lot more energetic than the plastics you are currently using as fuel. One bot about that is that the exhaust will contain aluminum oxide which will cause serious erosion/abrasion of your nozzle throat. Just a heads up. I hope you found this helpful, and if you ever have any questions about rocket engines/technology I'd be happy to chat. Keep up the great work and stay safe!

mitchelwendland

video idea: use the 3d printed metal to make more sturdy gears and make a functional vehicle with them.

christinemanson

To much oxygen, reduce it so that nearly no unburned oxygen reaches the aerospike otherwise even tungsten will burn uo

_Matyro_

this is one of the most amazing thing i have ever seen. The thought pf 3d printing metal at home is just amazing! Thanks man for showing this to us.

idiotsandwich

If you've got an excess of Oxygen going through the nozzle, then it's going to act like an oxy/acetylene torch where the heat plus the O2 burns the steel away, destroying the nozzle in the process.

taylorgalilea

Turned out beautiful! Looks pretty time intensive though.
I think it'd be pretty interesting to try printing a tensile test bar with it, and compare it to homogeneous mild steel -- see how much strength you lose with sintering vs e.g. machining. Although I guess for rocket engines yield strength doesn't really matter haha

Built_IRL

Try making a wrench of that metal fillament, they tighten a blot so we can really see how strong it is in practical applications

jesselopez

If you're already in the business of sintering metal, perhaps you could build a nozzle from layered sheets of metal cut out by a water jet cutter, or laser.

World_Theory

Print the nozel in a way, that the Fuel/Oxidizer first runs through cooling ducts on the nozel and then burns away
(Thats what actual rockets do sometimes)

Hendiadyoin