Case Study: German Aerospace Center achieves 30:1 parts-count reduction and improved combustion efficiency with 3D Systems' metal 3D printing

German Aerospace Center (DLR) Designs Liquid Rocket Engine Injector with 3D Systems

The German Aerospace Center (DLR) partnered with 3D Systems on the EU-funded SMILE Project to develop a reusable LOX/kerosene rocket engine injector for a small-satellite launcher. Faced with a highly complex injector head that required advanced cooling, integrated sensors and a design suited for refurbishment and reuse, DLR needed a solution that reduced assembly complexity, weight and production lead time.

Using Design for Additive Manufacturing expertise and metal 3D printing on a ProX DMP 320 in LaserForm® Ni718, 3D Systems produced a monolithic, highly integrated injector head with fine cooling and sensor channels. The new design cut the injector from 30 parts to one, reduced weight by 10%, eliminated tooling to accelerate design cycles, and delivered strong hot-fire performance with improved mixing and combustion efficiencies.

German Aerospace Center

Markus Kuhn

Manager, Injector Head Project