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With the E-2 Liquid Rocket Engine, Metal Additive Manufacturing Is Improving Critical Rocket Engine Performance

There is no doubt that satellites play a critical role in our lives. They not only provide information about Earth’s clouds, oceans, land and air (thus allowing scientists to predict weather and climate), but they are also critical for daily…

With the E-2 Liquid Rocket Engine, Metal Additive Manufacturing Is Improving Critical Rocket Engine Performance
3Dnatives

There is no doubt that satellites play a critical role in our lives. They not only provide information about Earth’s clouds, oceans, land and air (thus allowing scientists to predict weather and climate), but they are also critical for daily communications and more. But did you know that satellites have been shrinking? Today, satellites are cheaper to produce because they are lighter than previous versions resulting in lower launch costs. As a result, companies are also moving to create smaller, lower-cost rockets to support them. One of the most notable on the market is Launcher.

Californian start-up Launcher was founded in 2017 to address increasing launch demand, which is outpacing supply in the satellite launch market (expected to grow from $8B to $38B in 2030). The company combines liquid propulsion technology and metal 3D printing to create efficient rockets and transfer vehicles to deliver small satellites to orbit. Notably, they have conceived the low-cost Launcher Engine-2 (E2) rocket engine which has been optimized for mass production. It is aimed to be the highest performance liquid rocket engine of its class and is destined to be the central thrust component for Launcher’s Light rocket. And to realize this innovative design, Launcher turned to Stratasys Direct Manufacturing and Velo3D’s metal AM technology.

Testing the engine (photo credits: Launcher/John Kraus Photography)

A Closer Look at the E-2 Liquid Rocket Engine

As mentioned, the Launcher E-2 liquid rocket engine has been designed to be part of Launcher’s high-performance rockets. The 22,000 lbf (pound-force) engine, propelled by LOX (liquid oxygen)/RP-1 (kerosene), is considered to be the world’s highest performing engine for small launches. 3D printed with a copper alloy, it has a 98% Combustion Efficiency and a performance of 365s Isp. Furthermore, thanks to its high balance, the LOX pump’s impeller can spin at 30,000 rpms in cryogenic conditions all while transporting liquid oxygen.