From a 4D vision to a 3D engine: Sustainability in space

With ISRO’s Reusable Launch Vehicle and solar power to power space engines last year, space innovations in India became frequent until recently, when a new level was unlocked. 

Agnikul Cosmos, a homegrown Indian space start-up has scripted history. Not only did it launch India’s first private rocket, it also is powered by a semi-cryogenic engine. But the this engine was 3D Printed!

For the unversed, 3-dimensional printing is a process that uses computer-aided design, or CAD, to create objects layer by layer. 3D printing is commonly used in manufacturing and automotive industries, where tools and parts are made using 3D printers and is also known as additive manufacturing.

Agnikul named this one-of-a-kind rocket as Agnibaan (a fire-arrow), and the 3D printing process only took 72 hours - with a nickel-chromium alloy, in 3 days, a whole engine was ready (powered by a 3D printer manufactured by a German company: EOS.) 

Essentially, what should take three to four months through a conventional rocket engineering manufacturing process, this took only 0.001% of the originally anticipated time.

Agnikul Cosmos, incubated at IIT Madras and took ISRO on board to create a strategy and framework for small-scale launch vehicles and making India debut in space from a commercial standpoint. 

I first read about them researching for an article when Agnibaan was under process but with 3D printing as a foundation of this extremely powerful arrow, the case of sustainability in space is only strengthened.

The emissions generated while launching a spacecraft are immense, and so is the energy-, waste- and carbon-footprint. Research suggests that 3D printing can reduce 40-50% of GHG emissions in comparison with traditional processes. While a 3D printer and its inputs would be substantially emission intensive itself, the reduced process time has a huge overall impact.

The idea of using 3D printing for space propulsion was brought in by Relativity Space, a US based company which is, in its own words, on a mission to become the next great commercial launch company. Their focus is on reusable rocket manufacture, while reducing vehicle complexity, cost and the time to reach the market. They believe that the future lies in 3D-printing, and in March 2023, they successfully launched Terran 1 - the world’s largest 3D printed object into space, measuring 100 feet tall and 7.5 feet wide. Terran 1 included nine additively manufactured engines made of an innovative copper alloy, which experienced temperatures approaching 6,000 degrees Fahrenheit. It is almost next gen to print out objects which can withstand spatial elements and extreme temperatures.

Using such a novel technology for space vehicles and small-scale launches tap into a whole new world. By allowing for precise material deposition, 3D printing reduces waste compared to traditional methods as we discussed, and this is crucial for expensive materials like titanium and Inconel used in rocket engines. It enables the creation of complex geometries, such as optimised cooling channels, and consolidates multiple parts into single components, reducing assembly needs and potential failure points. This technology accelerates innovation by allowing faster prototyping and iteration, lowering manufacturing costs through reduced material waste and simplified assembly. 

In terms of space sustainability, 3D printing produces lightweight components, leading to fuel savings and lower emissions. It enables on-demand manufacturing in space, which Agnibaan achieved and also reduces the need for extensive supply launches from Earth, and some systems can use recycled materials, minimising waste. 

Apart from Agnikul and Relativity, Elon Musk’s SpaceX has been using N 3D-printed components in the SuperDraco engine and NASA has also been developing and testing 3D-printed rocket engine injectors, thereby enhancing sustainability and efficiency in space missions. It also helps in lessening space debris which is the biggest challenge for the future, as well as makes resource mining a potential future process.

India and its tryst with space has been transformational ever since the time of Vikram Sarabhai and A.P.J Abdul Kalam, but in less than 65 years where we are spearheaded as a country is absolutely remarkable and that is such an understatement. Companies like Agnikul Cosmos, Dhruva Space, Aadyah Aerospace, Blue Sky Analytics amongst others are scripted history one idea at a time. The future is here, the future is within us.

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