U.S 

Aerojet Rocketdyne is developing a hypersonic propulsion prototype using additive manufacturing techniques under a $22 million contract with the US Department of Defense. This initiative aims to streamline production processes and enhance efficiency in creating complex components for advanced hypersonic airbreathing systems.

The US Department of Defense Manufacturing Technology Program has recently awarded Aerojet Rocketdyne a significant contract to develop a hypersonic propulsion prototype. This initiative falls under the Growing Additive Manufacturing Maturity for Airbreathing Hypersonics (GAMMA-H) challenge program, with a budget of $22 million allocated for the project.

The objective of this endeavor, spanning 36 months, is to streamline the manufacturing process for hypersonic propulsion systems using additive manufacturing techniques. By consolidating various essential steps in the production chain, Aerojet Rocketdyne aims to enhance efficiency, reduce costs, and accelerate production timelines.

Ross Niebergall, President of Aerojet Rocketdyne, highlighted the importance of optimizing processes to increase part yields and minimize processing steps. This optimization is expected to result in higher production rates and lower overall costs.

The GAMMA-H program is part of broader Pentagon efforts to modernize manufacturing processes for hypersonic weapons components. Traditional methods often struggle to meet the intricate geometric specifications required by advanced hypersonic systems. Through additive manufacturing, these limitations can be overcome, enabling the production of complex components that meet the stringent requirements of modern hypersonic airbreathing systems.

Deputy Director Keith DeVries emphasized the significance of embracing additive manufacturing technology to push the boundaries of materials production. While the potential of additive manufacturing has been demonstrated, widespread adoption has yet to be achieved. The GAMMA-H program aims to catalyze further adoption of this transformative technology within the defense manufacturing sector.

Additive manufacturing involves the use of computer-aided design software to create a detailed blueprint of the desired object. This blueprint is then translated into a series of layers, which are sequentially fabricated by a 3D printer. This process enables the creation of intricate parts and products that would be challenging to produce using traditional subtractive manufacturing methods, where material is cut away from a solid block until the final product is formed.

In summary, the partnership between Aerojet Rocketdyne and the US Department of Defense represents a significant step forward in the advancement of hypersonic propulsion technology. By leveraging additive manufacturing techniques, the project aims to enhance efficiency, reduce costs, and accelerate the development of critical components for hypersonic airbreathing systems, ultimately bolstering national defense capabilities.