The Challenge:
Traditional manufacturing methods for rocket engines required complex assemblies, multiple brazed joints, and heavy wall thicknesses to withstand extreme conditions. Karman Space needed a new solution to build a lightweight, regeneratively cooled thrust chamber capable of operating in both cryogenic and high-thermal environments — and to do it faster than conventional manufacturing would allow.

The Solution:
In collaboration with Nikon SLM Solutions, Karman Space Programme harnessed the capabilities of Selective Laser Melting (SLM®) to:

• Integrate cooling channels directly into the thrust chamber wall using Inconel 718.
• Optimize wall thickness to just 0.5mm while maintaining structural integrity.
• Manufacture the engine as a single piece, eliminating brazed joints and reducing failure risks.

The Impact:

• Record-Setting Thrust: Achieved 7.2kN during a hot-fire campaign.
• Full Reusability: No repairs required after qualification tests.
• Accelerated Development: From clean-sheet design to successful hot-fire testing in less than one year.
• Enhanced Efficiency: Improved combustion stability and thermal performance without the need for supplementary cooling.

Discover how Nikon SLM Solutions’ additive manufacturing technology empowers the next generation of aerospace innovation. Download the Case Study now.