NASA updates on progress of RAMPT program to advance DED

additive manufacturing to create stronger, lighter rocket parts
Full scale 3D printed RS-25 engine could reduce costs by up to 70%.

NASA’s Marshall Space Flight Center in Huntsville, Alabama, has pioneered additive manufacturing to create stronger, lighter rocket parts. Launched in 2020, the Rapid Analysis and Manufacturing Propulsion Technology, or RAMPT, project, led by co-principal investigator Paul Gradl, focuses on developing new alloys and manufacturing processes such as DED of large parts.

RAMPT has achieved significant milestones, including 12 hot-fire tests with 3D printed thrust chamber hardware and demonstrating 40% weight savings with composite materials. The project has conducted over 500 test firings, utilizing new alloys and large-scale additive manufacturing processes. A key achievement is the development of a full-scale version of the RS-25 engine, potentially reducing costs by up to 70%.

The graphic captures additive manufacturing technology milestones led by the RAMPT project. Using 3D-printed, liquid oxygen/hydrogen thrust chamber hardware at chamber pressures of up to 1,400 pounds per square inch, Marshall engineers have completed 12 hot-fire tests totaling a combined 330 seconds. The project also has delivered composite materials demonstrating a 40% weight savings over conventional bimetallic combustion chambers. NASA and its industry partners are working to make this cutting-edge technology accessible for a host of future NASA and commercial space missions.
NASA/Pablo Garcia

NASA’s Marshall Space Flight Center in Huntsville, Alabama, has pioneered additive manufacturing to create stronger, lighter rocket parts. Launched in 2020, the Rapid Analysis and Manufacturing Propulsion Technology, or RAMPT, project, led by co-principal investigator Paul Gradl, focuses on developing new alloys and manufacturing processes such as DED of large parts.

RAMPT has achieved significant milestones, including 12 hot-fire tests with 3D printed thrust chamber hardware and demonstrating 40% weight savings with composite materials. The project has conducted over 500 test firings, utilizing new alloys and large-scale additive manufacturing processes. A key achievement is the development of a full-scale version of the RS-25 engine, potentially reducing costs by up to 70%.

“Our primary goal with these higher-performance alloys is to prove them in a rocket engine test-fire environment and then hand them off to enable commercial providers to build hardware, fly launch vehicles, and foster a thriving space infrastructure with real scientific, social, and economic rewards,” Gradl said.

The RAMPT project not only develops new technologies but also advances simulation tools to assess materials at a microstructural level. This approach significantly shortens the design-fail-fix cycle, enabling rapid prototyping and testing.

The RAMPT team received NASA’s 2024 Invention of The Year award for their contributions to deep space exploration. The project is supported by various NASA centers, academic partners, and industry contractors, funded by NASA’s Game Changing Development Program within the Space Technology Mission Directorate.

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