Synopsis
Additive manufacturing (AM) processes are proving to be a disruptive technology and are grabbing the attention of the propulsion industry. AM-related advancements in new industries, supply chains, design opportunities, and novel materials are increasing at a rapid pace. The goal of this text is to provide an overview of the practical concept-to-utilization lifecycle in AM for propulsion applications. As with any new process, it’s tempting to get caught up in the excitement of AM and its application and to give little forethought to the potential economic and technical challenges. This text is intended to help AM adopters to be intentional as they apply these technologies, and to understand the basis for the lifecycle of AM components. It is a practical guide based on lessons learned and experiences with both successes and in failures in AM. The organization of this text seeks to guide an engineer through the intertwined basics, regarding design and implementation, as they begin their journey into AM. The book is also relevant for veteran AM users as a reference. While AM is still in the development phase and continues to evolve, the fundamental lessons learned remain of great value even as forthcoming technology emerges. While many metal AM processes are referenced, the book focuses on those with more industry maturity, including powder bed fusion and directed energy deposition.
About the Author
PAUL R. GRADL is a principal engineer and subject matter expert at the NASA Marshall Space Flight Center. He has led several projects across NASA for additive manufacturing of liquid rocket engine components supporting various development and flight programs since 2004. He is an Associate Fellow of AIAA, recipient of “Engineer of the Year” by AIAA in 2022, serves as an industry advisor in additive, and was named one of “The Most Influential Personalities of Additive Manufacturing in 2020.” He holds a master’s in engineering, MBA, and is a PhD candidate in Aerospace Engineering. CHRISTOPHER PROTZ is the advanced manufacturing technology lead at the NASA Marshall Space Flight Center (MSFC). where he coordinates the evaluation, development, and integration of terrestrial and in-space manufacturing technologies/capabilities for NASA and partner programs. He has been with MSFC since 2004 and has deep experience in design, analysis, manufacturing and testing of liquid rocket engine components, spacecraft, and vehicle systems. He holds a bachelor’s, master’s, and PhD from the Massachusetts Institute of Technology in Aerospace Systems. OMAR R. MIRELES is a research engineer at the NASA Marshall Space Flight Center. He serves as principal investigator for several additive manufacture research and development projects and infusion of additive manufacture into propulsion, power, cryogenic fluid management, and nuclear systems. He holds a PhD in Nuclear Engineering with emphasis in Materials Science and Engineering with work experience since 2002 at several NASA centers, Oak Ridge National Laboratory, and the U.S. Air Force. CHANCE GARCIA is a lead engineer in propulsion systems engineering at the NASA Marshall Space Flight Center. He has experience with propulsion systems development for design, analysis, manufacturing, and testing of additive components. He holds a bachelor’s, master’s, and PhD from the University of Texas El Paso. He is a graduate of the International Space University Studies Program, and an advisor and session chair for various STEM activities and conferences.
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