Agile Space Industries (Agile) is entering into a collaboration with 6K Additive, which is part of 6K and specialises in producing materials for additive manufacturing. Agile plans to use this powder to produce critical components are of rocket engines. The company is currently working on certifying Nickel 625 (Ni625) powder for 3D printing applications of customers focused on aerospace.
US-based Agile focuses on manufacturing thrusters and rocket motors. Agile has existed since 2019, when it emerged from the merger of Agile Space Propulsion and Advanced Mobile Propulsion Test. The company acquired US-based Tronix3D in 2021, from which its subsidiary Agile Additive was formed. This organisation focuses specifically on additive manufacturing in metal, targeting aerospace and defence applications.
Chemical motors
The motors the company produces are so-called 'chemical motors', which run on chemical energy. Specifically, these are hydrazine and hydrazine-based compounds. The drives are aimed at space use. The company produces the thrusters and rocket using additive manufacturing.
The company plans to use 6K Additive's Ni625 powder to produce parts for its A2200 hypergolic bipropellant motor. These run on a pressurised hypogolic bipropellant. The fuel consists of a combination of hydrazine, M20 and the MON3 oxidant. These ignite as soon as they come into contact, meaning the engine does not need to be ignited.
Low weight combined with high thrust
The A2200 motor weighs just 5.9 kilograms, while delivering 500 pounds of thrust. The company claims this is possible thanks to the use of additive manufacturing.
Kyle Metsger, director of Additive Technology at Agile, explains: "By weight, 85% of our engine components are additively produced. This means we rely heavily on AM powders that can withstand the extreme temperatures and forces released during take-off and during flight. 6K Additive enables us to produce additive using the high-quality powders necessary for our critical applications, while helping us meet our sustainability goals through our recycling programme and sustainably produced powders. 6K Additive can provide extremely consistent powders that enable our production lines to run the long production times necessary for these complex components."
Development cycle shortened from two decades to one year
The use of additive manufacturing also means that Agile can develop new thrusters and rocket engines significantly faster than usual. Such a development cycle normally takes around two decades for aerospace components. Agile reports being able to complete this process in just 12 months thanks to additive manufacturing.
Agile's A2200 engines are designed for use on a lunar lander. The engine is designed for demanding missions. For example, the motors can burn for more than 318 seconds continuously. In addition, the engine is capable of 'deep throttling'. This is a manoeuvre that spacecraft perform if they try to land on an unknown surface. The manoeuvre allows the propulsion to be precisely controlled to ensure a smooth and controlled landing.
Frank Roberts, president of 6K Additive: "We are always excited to work with customers like Agile, who use our high-quality powders to produce crucial rocket components to land on the moon. The fact that we can enable space exploration while remaining at the forefront of sustainability at home on Earth is the best of both worlds. Agile has a cradle-to-grave mentality when it comes to its products, and the fact that 6K Additive supplies the company with high-quality, sustainably produced Ni625 and provides an established waste stream to help with environmental management aligns with our mission to exceed our customers' expectations."
Author: Wouter Hoeffnagel
Photo: LoganArt via Pixabay
