EOS and Hyperganic 3D Print More Efficient Space Propulsion Components

The German manufacturer EOS recently signed a partnership with Hyperganic, a company based in Munich, which develops algorithmic engineering software based on artificial intelligence. The goal of this cooperation in is to integrate the Hyperganic core platform with EOS’ 3D printing solutions and thus enable the design of complex and optimized parts for additive manufacturing processes. One of the first achievements of this strategic partnership is an aerospike rocket engine, which is characterized by its complex design. At first, the engine was 3D printed from a nickel alloy and later made from copper in a larger volume.

Founded in 2015, Hyperganic quickly became a key player in the additive manufacturing design industry. It has developed software that can reproduce nature-inspired shapes and automate each design step to the highest possible degree. In the case of this solution, it relies on algorithms and artificial intelligence to optimize the performance of the 3D printed part. When we met with the company in 2019, its goal was to diversify its partnerships and get closer to 3D printer manufacturers. A plan it has successfully implemented by recently signing the new agreement with EOS. Lin Kayser, CEO of Hyperganic, says, “we are very excited to partner with EOS in this industry-first collaboration. Algorithmic Engineering translates ideas into designs in minutes, with the engineer setting the rules and the computer generating the results. Specifically, the field of space propulsion which still uses very conservative designs, will benefit greatly from Algorithmic Engineering.”

Photo Credits: EOS / Hyperganic

EOS and Hyperganic advance the field of space propulsion

Keeping that in mind, the two companies created a 3D printed aerospike rocket engine. Hyperganic’s teams came up with an innovative design based on an algorithmic model. Several hundred iterations were generated and one of them was 3D printed on an EOS M 400-4 machine, without an additional support and using NickelAlloy IN718. This is a major challenge, as this type of engine requires a deconstruction of the a conventional engine design and therefore results in a more complex redesign. It’s important to remember that aerospike nozzles are designed to optimize propulsion efficiency over a wide range of altitudes.