British company Orbex presents Prime, a new rocket that the company says is the most efficient method of launching satellites. The Prime features a rocket motor produced using a 3D printer.
It is a so-called stage 2 rocket, which is used to put a rocket into orbit after its launch. The stage 2 rocket is made of a specially developed lightweight composite of carbon fibre and aluminium. Orbex claims that its rocket is 30% lighter and 20% more efficient than any other available lightweight rocket that can be used to launch satellites. The company also says the rocket delivers more power per cubic litre than much heavier alternatives.
3D printed rocket engine
A striking feature of the Prime is the rocket motor, which has been manufactured using a 3D printer. The engine was produced by Orbex, which specialises in additive manufacturing. The rocket motor is printed as one part and contains no transitions such as welds. This is important, as this creates weak spots that could cause problems due to the extreme fluctuations in temperature and pressure the material is exposed to during its journey to space.
Details about the printing process have not been disclosed. However, it is known that Orbex has collaborated with SLM Solutions, a German company specialising in additive manufacturing, to produce the rocket motor. SLM Solutions supplies additive manufacturing systems based on Selective Laser Melting (SLM). In this 3D printing technique, metal powder is cured using a laser. By precisely controlling this laser and curing the material only at specific spots, it is possible to print an object layer by layer.
Printing moving components
Because objects are built up layer by layer at SLM, it is possible to print shapes and structures that cannot be manufactured using other production methods. For example, it is possible to print an object including moving parts in a single session. Orbex and SLM Solutions use this feature to print a fully functional rocket engine in one go and from one piece.
Orbex reports that the Prime is not only the first rocket with a 3D printed rocket motor, but also contains the first commercial rocket motor that runs on biopropane. This is a clean and sustainable fuel that Orbex says produces 90% less CO2 emissions than traditional internal combustion engines. The biopropane this engine uses is supplied by Orbex's partner Colar.
Payload shock-free delivery
Also notable about Prime is the use of a system called 'Magic', which Orbex says allows the Prime's payload to be delivered "shock-free" into space. Among other things, this method prevents debris from being left in space during launches. The payload is carried in a special cargo bay, which has a diameter of 1,300 mm. Orbex claims that this puts Prime in the lead in its class in terms of the size of satellites that can be transported.
The Prime should eventually be used to launch satellites for Orbex customers. In July 2018, for instance, it was announced that Orbex had been selected by the UK Space Agency to provide launches from launch pads at Sutherland in the Scottish Highlands as part of a consortium. Prime's first flight is scheduled for 2021 During this flight, an experimental payload from UK company Surrey Satellite Technology will be carried.
Swiss company Astrocast has also signed a deal with Orbex. The British company will handle the launch of several nanosatellites for Astrocast, which will become part of a global Internet of Things network that Astrocast is working on. This network should eventually consist of 64 nanosatellites orbiting the Earth.
Orbex will launch a dozen nanosatellites for technology company Deimos Space.
Author: Wouter Hoeffnagel
Source: Orbex
