With new advances in aerospace technology, SpaceX recently launched its first reusable rocket, and Virgin Galactic is committed to bringing commercial space travel to the public (Branson, 2018).
Technology startup Relativity Space has made some interesting advances in space technology. Due to the advanced integration of intelligent robot technology and advanced 3D printing technology into the manufacturing process, it is at the forefront of the aerospace industry (Relativity Space, 2020).
The company has joined many new companies, and its vision is to make humans an interplanetary species by establishing settlements on Mars. Although no one is on this red planet, there are still a series of Rover launches to study the planet’s topography and atmospheric conditions. Settling on Mars is not an easy task, because there are many hazards, from radiation exposure on the surface of the planet to lack of oxygen in the atmosphere. All aspects of the mission must be analyzed, and in order to make it economically feasible, innovation must be made in the basic way of making rockets.
Relativity Space proposes to use additive-made 3D printed rockets. Additive manufacturing is the process of combining different materials to construct objects based on 3D model data (GE Additive, 2017). The layers above this material layer are added in precise geometric shapes to create parts, thus providing better flexibility in the way parts are manufactured.
A 3D printer called Stargate can print parts up to 20 feet high and 10 feet wide. This is in contrast to the traditional manufacturing process, which mainly involves subtracting blocks of material through machining, engraving or milling to build the design components.
There are several advantages of applying 3D printing to the aerospace industry. Additive manufacturing can speed up the innovation process because multiple iterations of the same design can be easily built and tested.
Relativity Space can make rockets in a fraction of the time normally required. Parts manufactured in this way are much lighter and stronger than conventionally manufactured parts. 3D printed parts simplify the manufacturing process and improve performance.
The use of 3D printing is not limited to manufacturing rocket parts. AI SpaceFactory is planning to 3D print the entire house to optimize residence on the surface of Mars. The Marsha project involves the use of fixed rover stations to construct vertical habitats using materials easily found on the surface of Mars. This innovative design stems from NASA’s 3D printing habitat challenge.
SpaceX ’s latest advancements in rocket reusability have made the times even more exciting. The ability to combine rapid rocket manufacturing with the reusability of these rockets will result in space missions usually costing only a fraction of the cost.
Relativity Space and NASA recently signed a 20-year partnership to use its Stennis Space Center. The transaction includes the exclusive lease of a 25-acre E4 test center to test Relativity Space ’s 3D printing engine.
Relativity Space will use the four test stands provided in the facility, making it possible to perform more engine tests before the final installation.
Relativity Space was established in 2016 and had previously undergone 124 combustion tests on a rocket engine first launched in 2021. To be able to 3D print the entire rocket, components need to be redesigned from scratch to reduce the complexity of construction.
Relativity is developing a new Aeon 1 engine, which has about 100 parts compared to the thousands of parts required to manufacture traditional engines (Berger, 2018). The Aeon 1 engine uses a mixture of methane and oxygen for propulsion, with a vacuum thrust of 19,500 lbs.
Relativity plans to use nine Aeon 1 engines in the first phase of the Terran 1 rocket. The height of the rocket is designed to be about 10 layers, and can be used to launch small and medium-sized to low Earth orbit, carrying a load of about 1250 kg. The company aims to use Stargate 3D printers to produce rockets in less than 60 days, such as Terran 1.
The launch cost of Terran 1 is about 10 million US dollars, while the average launch cost of SpaceX is 60 million US dollars.