RCI completes testing of its Comet series of Hybrid 3D printed rocket engines

China3D printingNet May 19th, the American space technology startup Rocket Crafters Inc. (RCI) has completed its Comet series Hybrid 3D printingRocket engine testing.
After completing 49 laboratory tests, the latest engine was designed as a large-scale proof-of-concept of Rocket Crafters’ STAR-3DTM hybrid rocket engine, ahead of the planned test flight time later this year. “
We are excited by the data we see and will soon be flying a rocket. “Rocket Crafters President Rob Fabian said, “The engine performance tested is in line with expectations on the model. “



The test of the Comet rocket engine has been completed. Image courtesy of John Kraus of Rocket Crafters.


Rockets and additive manufacturing


The Florida-based aerospace company has been developing its hybrid technology with the goal of providing a more reliable and affordable alternative to launch payloads into orbit.
Rocket Crafters’ patented engine design method combines3D printingThe solid rocket fuel particles and liquid propellant are trying to take advantage of the two methods.
Although the solid propellant continues to burn until it is exhausted,3D printingAllows to print fuel in a specific pattern to determine how the propellant burns. in addition,3D printingThe consistency and reliability of solid propellant fuel are improved, and the problem of excessive vibration generated by traditional propellants is alleviated.According to China3D printingWang understands that hybrid engines are cheaper, faster and safer than equivalent liquid propellants, and have the ability to throttle and restart.


In July 2017, the Defense Advanced Research Projects Agency (DARPA) awarded the company a research contract of US$542,600 to develop its3D printingRocket fuel engine. As part of the research agreement, Rocket Crafters was allowed to test flight-capable rocket engines using a special test rig located on the Florida Space Coast to evaluate the rocket’s throttle and emergency engine shutdown capabilities.



3D printingEngine parts of a hybrid engine driven by a machine, ready to be assembled. Picture from Rocket Crafters.

test3D printingRocket


These tests were conducted at the company’s facility about 20 miles south of the Kennedy Space Center in Cocoa, Florida, during the past three months. The Comet rocket has been tested in the laboratory with a thrust of 250-500 pounds, but since February, the rocket has used a complete 5000-pound thrust engine, which is the largest version of the experimental engine to date.
Of the three tests, two were successful and closely matched the company’s performance model, but the third had an abnormal overpressure, which damaged the test bench and engine.
The analysis concluded that the engine’s auxiliary components initially failed, causing excessive pressure in the combustion chamber. The Rocket Crafters team insists that there is no problem with the STAR-3DTM core engine design, and the test can still be considered successful in terms of research and development.


FabianSaid: “This is why we conducted the test, we found and fixed the problem in the test, so we will not put it on the launch pad. We are moving from here.”
Rocket Crafters plans to conduct its first test flight later this year, which will be powered by a smaller version of the STAR-3DTM hybrid rocket engine. Two larger test flights will then be carried out into orbit, and the Dreadnought small satellite launch vehicle will be used to provide commercial services to low earth orbit, although the dates for these launches have not yet been determined.



The 5,000 lbf engine is ten times more powerful than the engine tested in the laboratory. Picture from Rocket Crafters.

Additive manufacturing and space launch

More and more companies are taking advantage of3D printingTechnology to develop different types of rocket fuel for commercial use.For example, scientists from James Cook University (JCU) in Australia have used3D printingThe fuel particles power the hybrid rocket engine.Using PLA with aluminum particles, it can be manufactured3D printingThe initial size of the round grains is 100mm in length, 20mm in diameter and 6mm straight circular burner. Although they performed poorly in the August 2019 test, the researchers believe this fuel has potential.

Gilmour Space Technologies, a Singaporean start-up, launched a3D printingHomemade rocket powered by fuel. The fuel, composed of two unnamed materials, powers a 3.6m long rocket that is launched into orbit from Queensland, Australia.The company received US$3.7 million in Series A financing in May 2017 to continue to develop and use3D printingRocket-fueled launch vehicle.

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