3D printing for rocket engines: faster & cheaper

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For the First Time, Error-Free Transitions between Nickel and Titanium

But flexibility alone is not enough if the transitions between materials become critical error potentials. Therefore, the researchers, in another project together with KU Leuven from Belgium, investigated how titanium and nickel alloys can be cleanly joined using multi-material laser melting. Initial tests—without an intermediate layer—however, showed partially defective transitions and brittle phases that had formed. Through simulations and laboratory tests, it was possible to prevent direct contact between the titanium and nickel alloy with a thin intermediate layer of molybdenum and to create a cohesive bond on a laboratory scale, the Augsburg (Germany) researchers are pleased to report. These results for the first time provide a basis for precise material transitions through intermediate layers, which is considered an important step toward lightweight, functionally integrated components.

EOS can be pleased, as the demand for the engine systems of its customer Beehive Industries (one can be seen in the picture) from the USA is increasing due to the global crises. Now there has been a nice order concerning 3D printers ... (Image:N. Leach-Proffer)

Now it's About Making the Whole Thing Economical ...

In order for the advantages of multi-material manufacturing to ultimately pay off economically and ecologically, the team led by scientist Constantin Jugert is also focusing on the processing and quality assurance of the metal powder. A magnetic separation system ensures that the powder, which gets mixed during printing, is automatically separated and reused—reducing material costs and emissions, according to reports. Looking ahead, real-time monitoring could be developed, where thermography and sensors monitor each melting layer live and automatically adjust the process parameters in a closed loop. This will be an important future research field to ensure consistently high component quality and to lay the foundation for scalable printing processes in the serial production of these rocket parts.

More About the Funded Rocket Engine Project

More than a dozen research institutions and industry partners are involved in the projects "Enlighten" and "Enlighten-ED," which are funded with around 38 million euros, until early 2027. As an industry partner, the ArianeGroup contributes the requirements for real-world space applications and prepares the integration into future launch vehicles. "We don't just want to demonstrate how multi-material 3D printing works today—with Enlighten, we are laying the foundation for sustainable, flexible series production of rockets that will make Europe more independent in the long term," says Constantin Jugert.

Contents of the article:

Page 1: Fraunhofer Researchers Push 3D Printing for Rocket Engines
Page 2: For the First Time, Error-Free Transitions between Nickel and Titanium

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Date: 08.12.2025

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Multi-Material to Space