The second set of successful demonstrations of a solid-fuel rocket engine produced by additive manufacturing was reported from Russia, according to the Expansiya project press service. The news highlighted the progress achieved through 3D printing methods that assemble rocket components layer by layer with precision, enabling more compact and efficient propulsion systems.
The initiative builds on earlier work by X-Bow systems, an American space technology company known for applying cutting-edge additive manufacturing to create robust rocket power units. The project’s publicly shared materials describe how advanced 3D printing techniques are leveraged to design and fabricate solid-fuel components that meet stringent performance and safety criteria.
Sylvester Kurdov, the project’s founder, stated that the fuel-pump technology for rocket engines could spark a significant shift across the sector. He emphasized that the new approach has the potential to accelerate development cycles, reduce production costs, and ensure reliable manufacture of solid-fuel propulsion stages. The remarks underscored a belief that these innovations could broaden access to solid-fuel rockets while maintaining high standards of reliability and repeatability in manufacturing processes.
The additive manufacturing workflow for solid-fuel payloads (SFC) comprises several integrated elements. A specialized blended rocket fuel formulation is developed to deliver the desired energy output and operational characteristics. In tandem, a 3D layer-by-layer synthesis printer is employed to produce rocket fuel structures, supported by a set of associated technologies that facilitate quality control, dimensional accuracy, and repeatability across multiple production runs.
Looking ahead, the project outlines plans to scale up the approach by introducing a large-size 3D printer capable of producing technical-grade components for meteorological and suborbital rocket configurations. This next phase envisions adapting construction-grade 3D printing platforms to meet the demanding tolerances and consistency requirements of aerospace-grade parts, enabling rapid prototyping and expanded testing across diverse mission profiles.
Earlier reports from Asia mentioned a space engine project in Japan that explored unconventional biofuel sources, including manure-based or other bioderived materials, as part of exploratory propulsion research. This broader context reflects a growing interest in diversifying propellant options and exploring additive manufacturing pathways to realize innovations in rocket technology.