NASA Marshall Space Flight Center, Huntsville, Alabama, recently announced that its engineers have tested the first 3D printed rocket engine igniter made of Inconel and a copper alloy. For this prototype igniter, the two metals a copper alloy and Inconel — were joined using a unique hybrid 3D printing process called automated blown powder laser deposition.
The prototype igniter was made as one single part instead of four distinct components that were formerly brazed and welded together in the past. This bi-metallic part was built during a single process by a hybrid machine made by DMG Mori in Hoffman Estates, Illinois. The new machine integrated 3D printing and computer numerical-control machining capabilities to make the igniter.