"Orbex recently introduced Prime, the world's largest metal rocket engine 3-D printed in a single piece," said an Orbex spokesperson. "The Orbex launcher not only uses 100% renewable fuel to cut carbon emissions by 90% and a zero-shock staging and payload separation resulting in zero orbital debris, but was also design-optimized for selective laser melting, helping to create a structure 30% lighter and 20% more efficient than any other launch vehicle in its category."
Orbex, a UK-based spaceflight company that develops small satellite launch vehicles, introduced Prime at the grand opening of its new headquarters in Forres, Scotland. Prime was 3-D printed on the SLM 800 large-format metal additive manufacturing (AM) system from SLM Solutions.
Orbex has received $40 million in public and private funding, from sources including the U.K. Space Agency and venture capital firms Sunstone Technology Ventures and High-Tech Gründerfonds, and has been able to attract top development talent with experience from leading space organizations including NASA, ESA and Ariane. Orbex aerospace engineers partnered closely with the applications engineering team at SLM Solutions headquarters in Lübeck, Germany, to ensure successful transfer of the design into selective laser melting production - a feat that required the partnership of the equipment provider due to the complexity and size of the component.
Lukas Pankiewicz, Applications Specialist, headed the consulting team inside SLM Solutions to develop a unique set of parameters optimized for this particular geometry. Working closely with the design team at Orbex, Pankiewicz consulted on the various design features and orientation options, while ensuring the part was built with the required material properties and dimensional accuracy. "Our aim during the process was to fulfill the quality expectations of the Orbex team, keep the functionality of the part and make it suitable for AM. Every single support structure used in data preparation has been customized to obtain the best quality in every section of the engine, taking post-processing into consideration as well."
The SLM 800 large-format metal AM system features a 260 mm x 500 mm powder bed that can build parts 800 mm tall, allowing the Prime engine to be built using a special nickel alloy in a single piece. The SLM HUB unpacking system for the SLM 800 integrates contactless powder handling and automated build chamber conveyors to transfer the finished part to an unpacking station designed to remove powder through vibration and rotation. Pankiewicz ensured a powder removal strategy was incorporated into the build with purpose driven delivery channels to be certain as much powder was removed from the build as possible while reducing material loss. After production, reference samples built together with the engine were analyzed in the SLM Solutions' metallography lab, where porosity level and distribution were proven to meet the quality acceptance criteria. "The rapid iteration times inherent to the SLM process allowed Orbex to realize both time and cost reductions - saving 90% in turnaround time compared to traditional CNC machining production," said the spokesperson.
"This has always been what SLM Solutions is about," said Dr. Axel Schulz, Chief Sales Officer of SLM Solutions. "Members of our team helped invent the selective laser melting technology. We have always wanted that technology to succeed - which is not just about selling SLM machines but creating that paradigm shift for the customer to be successful with their process. SLM Solutions consulted Orbex on how to make the technology best work for them and transferred that knowledge to ensure their successful implementation as they ramp up to production."
Jonas Bjarnoe, Chief Technology Officer of Orbex, said: "The SLM Solutions team showed true dedication and in-depth knowledge of our work. I am 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."
For more information contact:
SLM Solutions NA, Inc.
48561 Alpha Drive, Suite 300
Wixom, MI 48393
248-243-5400
info@slm-solutions.us
www.slm-solutions.us