{"id":4219,"date":"2023-10-09T10:43:53","date_gmt":"2023-10-09T10:43:53","guid":{"rendered":"https:\/\/scantechvn.com\/ung-dung\/dau-phun-dong-co-ten-lua-cua-trung-tam-hang-khong-vu-tru-duc-dlr-duoc-thay-the-bang-phuong-phap-in-3d-kim-loai-cua-hang-3d-systems-my\/"},"modified":"2024-04-10T04:27:45","modified_gmt":"2024-04-10T04:27:45","slug":"dau-phun-dong-co-ten-lua-cua-trung-tam-hang-khong-vu-tru-duc-dlr-duoc-thay-the-bang-phuong-phap-in-3d-kim-loai-cua-hang-3d-systems-my","status":"publish","type":"mona_application","link":"https:\/\/scantechvn.com\/en\/ung-dung\/dau-phun-dong-co-ten-lua-cua-trung-tam-hang-khong-vu-tru-duc-dlr-duoc-thay-the-bang-phuong-phap-in-3d-kim-loai-cua-hang-3d-systems-my\/","title":{"rendered":"Replace DLR’s rocket engine nozzle with 3D Metal 3D printing method from 3D Systems"},"content":{"rendered":"\n

The European Union’s Horizon 2020 project called\u00a0SMall Innovative Launcher for Europe\u201d\u00a0(also known as Project SMILE) aims to design components to\u00a0launch small satellites (about 150 kg) into solar orbit ( 500km). The Institute for Structure and Design of the German Aerospace Center (Deutsches Zentrum f\u00fcr Luft- und Raumfahrt , headquartered in Stuttgart, Germany, is one of 14 participating organizations and is responsible for its development; focusing on innovation Create and reuse systems, providing optimal cost-saving solutions.<\/p>\n\n\n\n

Markus Kuhn and Ilja M\u00fcller, Injector Head Project Managers, DLR said:
“3D Systems’ Metal 3D printing technology combined with smart design solutions has helped us realize many ideas in a short time.”<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n

CHALLENGES<\/strong><\/p>\n\n\n\n

Due to the complex structure of the injector head component of the liquid oxygen engine, DLR collaborated with 3D Systems Customer Center (CIC)  in Leuven (Belgium) to deliver 3D printing and design solutions Metal intended to meet DLR requirements.<\/p>\n\n\n\n

3D Systems’ Leuven CIC is one of four centers worldwide dedicated to advancing advanced applications by providing customers access to the resources needed to develop, validate and commercialize products. their products.<\/p>\n\n\n\n

SOLUTION<\/strong><\/p>\n\n\n\n

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By choosing Coaxial Nozzle Metal 3D Printing (DMP), DLR sought to take advantage of some of the key benefits of 3D printing, including:
Reduced parts count with unibody design as well as Integration of key features such as cooling channels for better overall propulsion system performance.
Markus Kuhn and Ilja M\u00fcller, project managers of the nozzle head at DLR, said they had carefully researched the list of metal printing technology companies in the world and decided to choose 3D Systems (USA) as a partner based on its successes in providing metal 3D printing solutions for aerospace applications
“Based on the success of initiatives for aerospace, we see 3D printing technology from 3D Systems (USA) as perfectly suitable to provide solutions for the production of injector heads, bringing new capabilities for sensor integration and fuel and coolant delivery,\u201d Kuhn said.<\/p>\n<\/div>\n\n\n\n

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\"\"
The 3D printed metal injector head has reduced weight by 10% and reduced assembly details by 29\/30: Speeding up the design cycle and minimizing production costs<\/em><\/figcaption><\/figure>\n<\/div>\n<\/div>\n\n\n\n

01. Optimize fuel injector design and reduce the number of parts<\/strong><\/p>\n\n\n\n

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The rocket’s injector is the part that pushes fuel and oxidizer into the combustion chamber. This system, if optimized, will improve performance and better control the combustion process needed to move the missile.
ANALYSIS OF SOLUTIONS TO REPLACE TRADITIONAL PRODUCTION WITH METAL 3D PRINTING SOLUTION FOR ROCKET ENGINE INJECTOR SYSTEM:
Optimize product performance through new designs for fuel and coolant distribution;Easy implementation of 3D temperature and pressure sensing channels;
Eliminate intermediate manufacturing and assembly steps; Independently optimize thermal, mass and hydraulic performance without the constraints of traditional fabrication methods;
Avoid assembly failure points and improve quality with unibody design;
Reduced machining steps to create a highly integrated and multifunctional injector.
By using metal 3D printing, DLR was able to drastically change the design approach of coaxial injectors and minimize the number of parts, contributing to a significant reduction in production time and costs.
Reducing the number from 30 parts to 1 part has contributed to a 10% weight reduction. Eliminating components that frequently fail means reducing quality control measures. This helps improve the performance of the entire system.<\/p>\n<\/div>\n\n\n\n

\n
\"\"
\"\"Th\u1eed nghi\u1ec7m \u0111\u1ea7u kim phun in 3D kim lo\u1ea1i c\u1ee7a h\u00e3ng 3D Systems (M\u1ef9) \u00a0cho th\u1ea5y hi\u1ec7u qu\u1ea3 tr\u1ed9n v\u00e0 \u0111\u1ed1t ch\u00e1y t\u1ed1i \u01b0u.<\/em>
Theo Koen Huybrechts \u2013 (K\u1ef9 s\u01b0 d\u1ef1 \u00e1n): \u201cC\u00f4ng ngh\u1ec7 in 3D kim lo\u1ea1i l\u00e0 gi\u1ea3i ph\u00e1p duy nh\u1ea5t \u0111\u00e1p \u1ee9ng y\u00eau c\u1ea7u v\u1ec1 hi\u1ec7u su\u1ea5t v\u00e0 l\u00e0m m\u00e1t \u0111\u01b0\u1ee3c t\u1ed1i \u01b0u h\u00f3a. \u0110\u01a1n gi\u1ea3n h\u00f3a s\u1ef1 ph\u1ee9c t\u1ea1p trong thi\u1ebft k\u1ebf c\u1ee7a c\u00e1c k\u00eanh c\u1ea3m bi\u1ebfn, \u00e1p su\u1ea5t v\u00e0 nhi\u1ec7t \u0111\u1ed9 , l\u1eafp r\u00e1p v\u00e0 s\u1ea3n xu\u1ea5t v\u1edbi c\u00e1c quy tr\u00ecnh nh\u1ea5t qu\u00e1n”.<\/em>\u00a0<\/figcaption><\/figure>\n<\/div>\n<\/div>\n\n\n\n

02. 3D printing process Metal nozzle parts for rocket engines<\/strong><\/p>\n\n\n\n

\n
\n

Software:  3DXpert\u2122 (3DXpert is an \u201call-in-one software\u201d)Metal 3D Printer (DMP): ProX DMP 320
Printing material: LaserForm \u00ae Ni718 (A) an Inconel alloy that resists oxidation and corrosion.
LaserForm Ni718(A) has tensile, fatigue, creep and fracture strengths at temperatures up to 700\u00b0C, and is therefore ideal for high temperature applications.
Post-print processing: Heat treated to completely remove support with electric discharge device (EDM).<\/p>\n<\/div>\n\n\n\n

\n
\"\"
Nozzle flow: blue: LOX; orange: kerosene; red: film layer; green: evaporative cooling.<\/figcaption><\/figure>\n<\/div>\n<\/div>\n\n\n\n

03.\u00a0 Completely replace traditional production methods. Speed up the design cycle<\/strong><\/p>\n\n\n\n

\n
\n

With 3D Systems’ available Metal material options, DLR has accelerated its experimentation with designs that bypass traditional mold making methods.
This capability is critical to the DLR design cycle, as it faces the “Time” problem. So, after just a few weeks they were leading the way for phase one design and moving into testing at speed.
\u201cThe combination of the ProX DMP 320 and 3D Systems’ knowledge of designing for Metal 3D printing has made it possible for us to test more design options in a much shorter time,\u201d said Kuhn and M\u00fcller. , say Kuhn and M\u00fcller.
Metal 3D printing allows DLR to apply a coaxial injection technique with a dual swirl injector element to optimize the oxidizer-fuel mixing of the injector tip.
Two different cooling solutions were implemented, each using small channels with a minimum feature size of 0.2 mm and a maximum length\/diameter ratio of 45.
The design also incorporates film forming in the injector tip, allowing engineers to adjust the film flow rate directly at the injector.<\/p>\n<\/div>\n\n\n\n

\n
\"\"
LOX \/ kerosene rocket engine setup with 3D printed injector and\u00a0ceramic combustion chamber.Image inside the injector tip shows the complexity of 30 parts fused into one monolithic part by machining metal 3D printing technology.<\/figcaption><\/figure>\n<\/div>\n<\/div>\n\n\n\n
RESULT
<\/strong>IMPROVE PERFORMANCE AND INCREASE PRODUCTION EFFICIENCY
Optimized part features: 10% weight reduction
Reduce 29\/30 assembly parts: Speed up the design cycle and minimize production costs
SUCCESS OF OTHER PROJECTS IN THE FIELD OF HKVT USING THE 3D METAL PRINTING METHOD (DMP) OF 3D SYSTEMS
3D Metal Printing (DMP) solutions have created important changes in the field of Aviation and Space because of the great benefits they bring, including:
Lose weight.
Energy saving.
Greater operational efficiency, component consolidation, increased time to market and reduced maintenance costs for components.
Recent projects that have demonstrated the effectiveness of 3D Systems’ 3D Metal Printing (DMP) technology in the aerospace sector include:
The first 3D printed radio frequency (RF) filter\u00a0has been tested and validated for use in commercial telecommunications satellites. Airbus Defense and Space’s new filter reduces weight by 50% compared to previous designs.
The titanium stand is 25% lighter\u00a0and has a better stiffness-to-weight ratio than traditionally manufactured stands, introduced through a collaboration between Thales Alenia Space and 3D Systems.
Engine parts\u00a0created by the European Space Agency (ESA) and 3D Systems in a project that saves weight, simplifies assembly, speeds production and allows stage design adaptation The last part is easier.
Airframe topology with optimization\u00a0reduces weight by 70% while satisfying all functional requirements and meeting GE Aircraft’s challenges. These requirements are implemented by the project\u00a0\u201cSMall Innovative Launcher for Europe\u201d coordinated by NLR, which has received funding from the European Union’s ‘Horizon 2020 Research and Innovation Programme’ under a funding agreement number 687242.<\/td><\/tr><\/tbody><\/table><\/figure>\n","protected":false},"excerpt":{"rendered":"

The European Union’s Horizon 2020 project called\u00a0SMall Innovative Launcher for Europe\u201d\u00a0(also known as Project SMILE) aims to design components to\u00a0launch small satellites (about 150 kg) into solar orbit ( 500km). The Institute for Structure and Design of the German Aerospace Center (Deutsches Zentrum f\u00fcr Luft- und Raumfahrt , headquartered in Stuttgart, Germany, is one of […]<\/p>\n","protected":false},"author":1,"featured_media":3500,"comment_status":"open","ping_status":"closed","template":"","meta":{"inline_featured_image":false,"footnotes":""},"taxonomy_application":[109],"class_list":["post-4219","mona_application","type-mona_application","status-publish","has-post-thumbnail","hentry","taxonomy_application-quan-su-hang-khong-en"],"acf":[],"yoast_head":"\nReplace DLR's rocket engine nozzle with 3D Metal 3D printing method from 3D Systems - Scantech<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/scantechvn.com\/en\/ung-dung\/dau-phun-dong-co-ten-lua-cua-trung-tam-hang-khong-vu-tru-duc-dlr-duoc-thay-the-bang-phuong-phap-in-3d-kim-loai-cua-hang-3d-systems-my\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Replace DLR's rocket engine nozzle with 3D Metal 3D printing method from 3D Systems - Scantech\" \/>\n<meta property=\"og:description\" content=\"The European Union’s Horizon 2020 project called\u00a0SMall Innovative Launcher for Europe\u201d\u00a0(also known as Project SMILE) aims to design components to\u00a0launch small satellites (about 150 kg) into solar orbit ( 500km). 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