Frankfurt, Germany, November 20, 2024 — LEAP 71, a Dubai-based company pioneering the new field of Large Computational Engineering Models, worked closely with Aconity3D, a leading company in metal additive manufacturing, to manufacture a 5 kN aerospike rocket engine using industrial 3D printing. The engine is shown at the Aconity3D booth at Formnext 2024. This innovative engine, designed autonomously by LEAP 71’s Noyron RP Large Computational Engineering Model and 3D-printed using Aconity3D’s advanced Metal Powder Bed Fusion (MPBF) technology, represents a significant advancement in rocket propulsion systems.
The aerospike engine, fabricated from CuCrZr—a high-performance copper alloy—utilizes cryogenic liquid oxygen and kerosene as propellants. Unlike traditional bell-nozzle engines, the aerospike design features a toroidal combustion chamber encircling a central spike, maintaining consistent efficiency from sea level to the vacuum of space. This design is particularly advantageous for applications with varying operating conditions, such as propulsive landing or single-stage-to-orbit missions.
The manufacturing process presented unique challenges, including managing shallow unsupported overhang angles and ensuring the integrity and surface roughness of the regenerative cooling channels. Aconity3D optimized scan strategies and print parameters to achieve exceptional quality, completing the 210 mm high thruster in under 62 hours using 6.9 kg of copper alloy. Post-processing involved professional powder removal by Solukon, utilizing their Pathfinder process, followed by heat treatment at the Fraunhofer Institute for Laser Technology.
This collaboration exemplifies the potential of combining Computational Engineering with advanced Additive Manufacturing to produce functionally integrated rocket engines. The aerospike engine, printed as a single component, minimizes the need for assembly and post-machining, streamlining the production process. LEAP 71 plans to conduct hot-fire testing of the manufactured aerospike in the coming weeks, with the capability to generate larger or smaller engines tailored to specific customer requirements.
For more information, visit LEAP 71’s website at https://leap71.com/ and Aconity3D’s website at https://www.aconity3d.com.
About LEAP 71
LEAP 71 is a global technology company headquartered in Dubai, UAE, pioneering the emerging field of Computational Engineering. Through advanced software algorithms, the company autonomously designs complex physical products. At the core of LEAP 71’s innovation is Noyron, a Large Computational Engineering Model that enables the rapid creation of sophisticated machinery without manual input.
In June 2024, LEAP 71 achieved a significant milestone by successfully test-firing a 3D-printed liquid-fuel rocket engine designed entirely using Noyron, demonstrating the transformative potential of its approach. Collaborating with global partners, the company is accelerating innovation across industries such as aerospace, electric mobility, and thermal systems.
For more information, visit: https://leap71.com
About Aconity3D
Aconity3D’s primary business focuses on developing advanced equipment for powder bed laser melting and direct energy deposition of metals. The company aims to combine maximum functionality with modular, open-ended machine concepts, all at competitive pricing tailored to specific customer requirements.
Currently, Aconity3D offers six fully-configurable machine models, catering to a broad spectrum of applications. This hardware portfolio is supported by hands-on training sessions, workshops, feasibility studies, and metal part production services for clients, creating a comprehensive solution for powder bed laser melting. As a result, this technology becomes accessible to a wider range of businesses, including small and medium-sized enterprises.
For more information, visit https://www.aconity3d.com
