f-1

Nasa has completed a series of tests on a 3D-printed part of the F-1 engine at its Marshall Space Flight Center in Huntsville, Alabama, US.

The rocket engine had been developed to propel the Saturn V rockets on missions to the moon.

In 2013, engineers tested a vintage F-1 gas generator on the same stand. The generator supplies power to fuel a pump that delivers propellant to the engine, and generates around 30,000lb thrust.

In the latest test, the team evaluated the capabilities of a gas generator produced using additive manufacturing techniques.

Engineers were able to compare the F-1 engine component built with one made using a traditional manufacturing.

Nasa Marshall Space Flight Center test requestor Chris Protz said: "This test gave Nasa the rare opportunity to test a 3D-printed rocket engine part, an engine part for which we have lots of data, including a test done three years ago with modern instrumentation.

"This adds to the database we are creating by testing injectors, turbo pumps and other 3D-printed rocket engine parts of interest to both Nasa and industry."

"If it proves to be a viable option, additive manufacturing may help us build future propulsion systems."

The test series was conducted for Dynetics and Aerojet Rocketdyne, who built the gas generator.

Nasa is working to identify future technologies and their applications in future propulsion systems.

Data accumulated from the tests of 3D-printed F-1 gas generator will assist Nasa and the aerospace industry to produce engine parts using the method, especially for a new Space Launch System (SLS).

The SLS’s first version of the rocket, Block 1, will be designed to launch 70 metric tonnes (mt) into low-Earth orbit. The next version, Block 1B, is expected to have 105mt lift capacity.

SLS advanced development task lead Sam Stephens said: "Nasa is exploring many technologies to enhance the SLS as it evolves for use in a variety of missions.

"If it proves to be a viable option, additive manufacturing may help us build future propulsion systems."

Image: The gas generator to an F-1 engine is test-fired at Nasa’s Marshall Space Flight Center in Huntsville, Alabama. Photo: courtesy of Nasa.