What if the next breakthrough in rocket propulsion wasn’t built—but printed? As the race to space accelerates, engineers are rethinking how rocket engines are designed and manufactured. Traditional methods rely on complex assemblies, extensive machining, and long lead times. But with additive manufacturing (AM), the paradigm is shifting—offering unprecedented advantages in cost, efficiency, and performance.

Karman Space Programme, in collaboration with Nikon SLM Solutions, is proving that AM isn’t just an alternative—it’s a superior solution. Their Cactus engine, manufactured on an SLM® Core, is pushing the boundaries of what’s possible in propulsion system design.

From Concept to Thrust: AM’s Role in Next-Gen Propulsion

For decades, rocket engines have been assembled from numerous individually machined components—welded or brazed together in intricate configurations. This process introduces weak points, increases weight, and limits design flexibility. Enter AM, a technology that eliminates many of these constraints by allowing engineers to fabricate complex geometries in a single build.

By leveraging Inconel 718, a high-performance aerospace superalloy, Karman Space Programme created an engine featuring integrated regenerative cooling channels. This design, nearly impossible with conventional manufacturing, enhances heat regulation and structural integrity—key to engine longevity and performance.

Why Additive Manufacturing is a Game-Changer for Rocketry

1. Optimized Design & Performance

• AM allows for monolithic structures, removing the need for joints and welds—eliminating potential failure points.
• Hollow-wall cooling channels efficiently regulate extreme temperature fluctuations, enhancing engine reusability.

2. Cost & Time Efficiency

• Traditional machining and assembly take weeks or months. AM dramatically cuts production time, enabling rapid prototyping and iteration.
• Fewer parts mean fewer potential failures, lowering maintenance requirements and improving reliability.

3. Scalability for Future Missions

• As space commercialization grows, reducing cost per kilogram to orbit is paramount. AM makes lighter, more efficient propulsion systems viable.
• The NXG XII 600 from Nikon SLM Solutions is already proving AM’s scalability, producing large-scale thrust chambers ready for high-thrust space applications.

4. Data-Driven Innovation

• Real-time data from hot-fire testing informs material behavior and thermal dynamics, continuously improving AM processes.
• These insights drive iterative enhancements, ensuring AM-built engines perform better with each generation.

Pioneering Reusability: The Business Case for AM

One of the biggest challenges in modern rocketry is achieving full reusability—a critical factor in reducing launch costs. By leveraging AM, Karman Space Programme has demonstrated that their thrust chamber can withstand multiple firings without significant wear. This isn’t just an engineering feat; it’s a business breakthrough. With each successful reuse, the cost-per-launch decreases, making AM-printed engines a financially sound investment for the future of space exploration.

The Next Frontier

As AM continues to prove its value in propulsion systems, the aerospace industry is taking notice. The transition from traditionally machined components to AM-built engines isn’t a question of “if”—it’s a question of “when.” And with companies like Karman Space Programme and Nikon SLM Solutions leading the charge, the future of space travel is closer than ever.

Our Mission, to Empower Yours

To learn more about how Nikon SLM Solutions can help you optimize your manufacturing processes, please contact our team.