New tech 3D prints rocket propulsion parts using multiple metals at once

Researchers at the Fraunhofer Institute have developed an innovative 3D-printing technique capable of simultaneously using multiple metals to manufacture critical rocket propulsion components in a single production run. This advancement, part of the EU’s €38 million “Enlighten” project, aims to reduce the number of individual parts needed, thereby cutting costs and development times for space programs like the European Space Agency (ESA). The process allows for precise placement of different metals—such as heat-resistant, magnetic, or lightweight alloys—within a single component, enabling the creation of more compact, lighter, and higher-performance rocket engines. For example, Fraunhofer successfully 3D-printed a rocket valve combining magnetic and non-magnetic steel in one step, a task that traditionally requires separate manufacturing and assembly. The new method addresses significant challenges in rocket engine manufacturing, which typically involves complex machining, welding, and bonding of many metal parts, each requiring rigorous testing. By integrating multiple metals in one print, the process minimizes potential