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The hot fire test was the culmination of a relationship between NASA and Elementum that began shortly after the company was founded in 2014 to make more materials available for 3D printing. Based in Erie, Colorado, the company infuses metal alloys with particles of other materials to alter their properties and make them amenable to additive manufacturing. This became the basis of Elementum's Reactive Additive Manufacturing (RAM) process.
NASA adopted the technology, qualifying the RAM version of a common aluminum alloy for 3D printing. The agency then awarded funding to print the experimental Broadsword rocket engine, demonstrating the concept's viability.
Meanwhile, a team at NASA's Marshall Space Flight Center in Huntsville, Alabama, was working to adapt an emerging technology to print larger engines. In 2021, Marshall awarded an Announcement of Collaborative Opportunity to Elementum 3D to modify an aluminum alloy for printing in what became the Reactive Additive Manufacturing for the Fourth Industrial Revolution project.
The project also made a commonly used aluminum alloy available for large-scale 3D printing. It is already used in large satellite components and could be implemented into microchip manufacturing equipment, Formula 1 race car parts, and more.
The alloy modified for the Broadsword engine is already turning up in brake rotors and lighting fixtures. These various applications exemplify the possibilities that come from NASA's collaboration and investment in industry.
Provided by NASA