Private US aerospace firmLauncher已经宣布了后处理系统制造商Solukonas its preferred supplier for powder removal systems.
The firm has integrated Solukon’s SFM-AT1000-S depowdering machine for the post-processing of large 3D printed rocket parts, including engines and combustion chambers.
“我们看到自动化粉末去除是生产过程中的重要一步，”发射器制造商蒂姆·贝里（Tim Berry）说。“为了进行最终的热处理和热等静止，压迫所有零件必须没有任何粉末，这是对具有难以访问的内部频道的大型和重型零件的特殊挑战。SFM-AT1000-S将有助于进一步自动化我们的生产过程，因为我们获得可靠且可重复的清洁结果。
“In addition, we benefit from Solukon’s experience and support when optimizing our fast and forward-thinking production lines.”
Launcher’s 3D printed rocket engines
Launcher的任务成立于2017年，是创造高效，具有成本效益的火箭，能够将小卫星运送到太空。收到一个$1.5 million US Space Force contract, the firm embarked on developing 3D printed components to enhance the performance of its E-2 engine.
So far, the E-2 engine is comprised of several 3D printed components, including a燃烧室一件印刷which is reportedly thelargest part of its kind, measuring 860mm tall. The engine’s parts are 3D printed in high-performance copper alloy and are engineered to require less propellant to get into orbit.
Launcher conducted thefirst full-scale test-fireof its E-2 engine injector and combustion chamber in October 2020, followed by a series of tests of its 3D printed liquid oxygen (LOX) turbopump, created in partnership with metal 3D printer manufacturerVelo3D.
The firm reached another milestone in thetesting of its 3D printed E-2 rocket enginelast year, having successfully completed a thrust chamber assembly hot fire test in August atNASA’s Stennis Space Center. The firm 3D prints its rocket components using its fleet of metal additive manufacturing platforms, which includes machines from Velo3D, EOS and AMCM.
Launcher’s E-2 engine is set to power the company’s Launcher Light vehicle, which aims to deliver payloads of up to 330 pounds to Low-Earth Orbit (LEO) by its first launch in 2024.
后处理火箭零件
尽管3D打印其火箭发动机组件在几何复杂性，成本效率和交货时间方面具有巨大的优势，但组件的冷却渠道和内部结构的去倍数可能会证明是复杂且耗时的。
The nature of the components can also make post-processing a hazardous process, with users faced with issues surrounding explosions, labor costs, powder recovery, and process repeatability among other things. In particular, 3D printing components in copper poses a particular depowdering challenge, as copper powder is susceptible to becoming sticky and clogging in a part’s cavities.
为了应对其中一些挑战，Launcher选择了Solukon的粉末去除系统来进行重新加工的重型火箭零件。公司的减速系统are driven by its proprietarySmart Powder Recuperation (SPR) technology, which deploys adjustable two-axis part rotation and targeted vibration to automatically remove excess powder from 3D printed parts.
Of particular benefit to Launcher, SPR is capable of completely removing unfused metal build material from complex channels and geometries in order to increase efficiency, safety, and quality of part production while simultaneously keeping costs down. As part of its new partnership with Solukon, Launcher has installed an SFM-AT1000-S depowdering system to completely free its rocket engines and combustion chambers from excess powder.
The SFM-AT1000S is an advancement of Solukon’s SFM-AT800-S system specifically designed for large and heavy parts. The system is capable of depowdering parts up to 600 x 600 x 1,000 mm in size and up to 800kg in weight, making it well-suited to the post-processing of aerospace parts and in particular, Launcher’s one-meter-high E-2 engine
The system is equipped with two endless rotating axes with programmable servo-drives that move the part along any imaginable path. Components can also be moved in any direction at varying speeds by use of a joystick, while the system’s optionalDigital Factory Toolensures quality assurance and automation integration of the depowdering process.
“Yet again, it’s an honor to support a leading new space company with our SPR technology,” said Andreas Hartmann, CEO and CTO of Solukon. “Shortly after the demand for a machine compatible with the AMCM M4K printer came up, we responded directly by developing the SFM-AT1000-S.
“I’m sure pioneers like Launcher will keep pushing the boundaries of what’s possible in additive manufacturing. Likewise, I’m sure we’ll always stand by their side with the ideal depowdering solution.”
Launcher and Solukon will officially announce their partnership at the upcoming Rapid + TCT 2022 show in Detroit, taking place between 17-19th May.
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特色图片显示the SFM-AT1000-S handles large parts weighing up to 800 kg. Image via Solukon.
