ULA Utilizes 3D Printing for Rocket Components

The United Launch Alliance (ULA) has implemented 3D printing into its production process for rockets and launch vehicles. The organization is a launch services company in the U.S. and serves agencies such as NASA and the Air Force.

ULA recently acquired two Fortus 900mc production systems from Stratasys. These systems will help ULA update the Environmental Control System (ECS) duct on the Atlas V, which will launch in 2016. It also selected the ULTEM 9085 thermoplastic for production.

By using 3D printing, ULA was able to reduce the number of parts in the ECS from 140 parts to 16. This, according to the company, reduces the installation time and has a 57% part-cost reduction. After the success of the Atlas V ESC, ULA will be using 3D printing for its upcoming Vulcan rocket.

“ULTEM 9085 has great strength properties over a wide temperature range,” said Greg Arend, program manager for Additive Manufacturing at ULA. “We have done testing to show that it is very capable of withstanding temperatures from cryogenic all the way up to extreme heat. And it’s tough enough to handle the vibration and stress of lift off and flight. We’re very satisfied with its performance. We see somewhat of an exponential growth in the utility of 3D printing for flight applications on our current vehicles, and we intend to use it heavily with our Vulcan rocket.”

For more information, visit United Launch Alliance.

Sources: Press materials received from the company and additional information gleaned from the company’s website.