Orbex Unveils World’s Largest Single-Piece 3D Printed Rocket Engine: Ushering in a New Era of Sustainable Space Launch
The burgeoning aerospace industry is constantly pushing the boundaries of innovation, seeking new ways to make space access more efficient, affordable, and sustainable. At the forefront of this revolution is British aerospace company Orbex, a pioneering firm dedicated to launching small, micro, and nano satellites into precise low Earth orbits. While Orbex has been steadily making strides in the commercial space sector, their recent revelation has sent ripples of excitement across the global space community: they have successfully manufactured the world’s largest 3D printed rocket engine. This monumental achievement is particularly noteworthy because the engine was printed in a single, monolithic piece, a feat of engineering that will significantly enhance the performance and reliability of Orbex’s flagship Prime rocket.
This groundbreaking announcement took center stage at the grand opening of Orbex’s new headquarters and rocket design facility in Forres, Scotland. The unveiling of the Prime rocket was a landmark event, attracting a distinguished roster of VIPs from both the UK and wider European space communities, alongside key local stakeholders. The Orbex Prime is not merely an incremental upgrade but a comprehensively re-thought and re-engineered two-stage rocket. Its sophisticated design is the brainchild of Orbex’s elite team of engineers, who bring a wealth of professional experience from some of the world’s most prestigious space organizations, including NASA, the European Space Agency (ESA), and ArianeGroup. Their collective expertise has culminated in a launch vehicle that embodies efficiency, sustainability, and cutting-edge manufacturing techniques.
Photo Credits: Orbex
Metal Additive Manufacturing: Revolutionizing the Aerospace Industry for Sustainable Futures
The heart of the Orbex Prime, its revolutionary rocket engine, owes its existence to the power of metal additive manufacturing. Specifically, it was intricately 3D printed using the state-of-the-art SLM800 metal 3D printer, a product of the renowned German additive manufacturing company SLM Solutions. This choice of manufacturing technology is pivotal, enabling Orbex to achieve geometries and consolidation of parts that would be impossible with traditional methods. Beyond its innovative construction, the Prime rocket is also meticulously designed with an unwavering commitment to environmental responsibility. Its advanced 3D printed engine, a testament to sustainable engineering, operates on 100% renewable fuel. This conscious decision is projected to drastically reduce carbon emissions by an astounding 90% compared to conventional rocket fuels, marking a significant stride towards mitigating the environmental impact of space launches. Furthermore, the Prime rocket incorporates a sophisticated zero-shock staging and payload separation system, an ingenious design feature that virtually eliminates the creation of orbital debris, a growing concern for the long-term sustainability of space operations and Earth’s orbital environment.
The adoption of metal additive manufacturing has provided Orbex with a transformative competitive edge. By leveraging this cutting-edge technology, the company has managed to slash its turnaround time for component production by an impressive 90% and reduce manufacturing costs by a substantial 50% when compared to more traditional production processes like CNC machining. This dramatic improvement in efficiency and cost-effectiveness is a game-changer for the aerospace sector, where speed and precision are paramount. Jonas Bjarnoe, the Chief Technology Officer of Orbex, enthusiastically praised the collaboration, stating, “The SLM Solutions team showed true dedication and in-depth knowledge of our work. I’m looking forward to continuing this collaboration in 2019 and onwards. Orbex and SLM Solutions have solved some important puzzle pieces which will change the space business.” This sentiment underscores the deep partnership and shared vision between the two companies, highlighting how their combined expertise is redefining the capabilities of rocket engine manufacturing.
Photo Credits: Orbex
A Pivotal Moment for the UK Commercial Space Industry and Global Connectivity
Beyond its innovative engine, the Orbex Prime rocket itself is a marvel of material science and engineering. Constructed from an advanced carbon fiber and aluminum composite, the vehicle boasts an exceptional strength-to-weight ratio, making it an astonishing 30% lighter than any other comparable vehicle in its category. This significant weight reduction translates directly into greater payload capacity and fuel efficiency, further enhancing its appeal as a sustainable launch solution. The highly anticipated maiden flight of the Orbex Prime, scheduled to launch from Scotland in 2021, promises to be a historic event. On board, the rocket will carry an experimental payload developed by UK-based Surrey Satellite Technology Ltd. (SSTL), widely recognized as the world’s leading manufacturer of small satellites. This inaugural launch will represent a monumental first for the burgeoning UK commercial space industry, cementing its position as a serious contender in the global space race and showcasing its homegrown capabilities.
Orbex’s commercial success extends beyond initial flights, as evidenced by its growing customer base. Switzerland’s Astrocast SA, a prominent player in the small satellite sector, has already signed up as a customer, planning to launch 10 nanosatellites aboard Orbex Prime in 2023. This launch is envisioned as a critical first step towards the ambitious development of a planet-wide Internet of Things (IoT) network. The long-term vision for Astrocast involves the deployment of a constellation of 64 nanosatellites, designed to deliver essential IoT connectivity to regions currently considered remote and underserved by traditional communication infrastructure. Orbex’s reliable and cost-effective launch services are instrumental in making such ambitious global connectivity projects a reality, unlocking new opportunities for industries ranging from agriculture to environmental monitoring.
On the financial front, Orbex has garnered substantial support, reflecting the confidence placed in its innovative approach and promising future. In July 2018, the company proudly announced that it had secured an impressive £30 million (approximately $40 million USD) in combined public and private funding. This significant investment came from a consortium of backers, including the crucial support of the UK Space Agency. This substantial financial injection not only validates Orbex’s technological advancements and business model but also earned it the distinction of becoming Europe’s best-funded private launch company at the time. Such robust financial backing ensures Orbex has the resources necessary to continue its research and development, scale its operations, and ultimately realize its vision of making space access more accessible and sustainable for a wide array of commercial and scientific endeavors.
The implications of Orbex’s achievements, particularly the world’s largest single-piece 3D printed rocket engine, are far-reaching. They highlight a paradigm shift in aerospace manufacturing, demonstrating how additive manufacturing can enable unprecedented design freedom, part consolidation, weight reduction, and faster iteration cycles. This not only makes rockets more efficient but also inherently more reliable by reducing the number of complex assembly points. As the demand for satellite launches continues to grow, driven by megaconstellations for global internet, Earth observation, and scientific research, the need for sustainable and efficient launch solutions becomes paramount. Orbex, with its Prime rocket and pioneering use of 3D printing, is perfectly positioned to meet this demand, leading the charge towards a new, greener era of space exploration and commercial utilization of low Earth orbit. Their commitment to renewable fuels and debris mitigation sets a new standard for responsible space activity, ensuring that humanity’s reach for the stars is conducted with the utmost care for our planet and the space environment.
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