Launch vehicles, spacecraft, and in-space services providerFirefly Aerospacehas announced it will transition its manufacturing of large parts to an Automated Fiber Placement (AFP) system fromIngersoll Machine Tools，从明年年初开始。
Once operational, Ingersoll’s AFP Mongoose Hybrid systems will allow Firefly to produce its all-composite Alpha rocket airframe in just two weeks.
“From the outset Firefly chose to utilize 21st century materials and manufacturing processes in our spacecraft and rocket designs,” said Dr. Tom Markusic, Firefly CEO. “Metallics were the most prevalent aerospace material of the last century; composites, which are stronger and lighter than metallics, are the choice for modern aircraft.
“ Firefly的Alpha是世界上最大的全碳纤维液体燃料火箭。”
利用AFP进行复合结构
While it’s not strictly a 3D printing technology, the use of AFP within the aerospace sector is significant, as is the involvement of Ingersoll. The company developed its宽和高添加剂制造（WHAM）雷电竞充值additive manufacturing system several years ago in partnership with橡树岭国家实验室(ORNL), initially targeting the aerospace, wind energy, automotive, and defense sectors.
Now, Firefly is looking to utilize Ingersoll’s high-speed, large-scale robotic AFP systems to essentially 3D print composite structures with large dimensions, a task which poses limitations when using metal 3D printing.
“Given that we can simply purchase machines which have been developed and proven by the aircraft industry and immediately achieve major cost, weight, and production time savings, it’s obvious to us that AFP is the most efficient and cost-effective approach to future rocket production,” continued Markusic.
萤火虫将首次安装法新社系统的manufacturing and test facility in Texas in May 2021, after which the Alpha rocket airframe will be requalified using AFP manufacturing processes. The second AFP system and automated assembly line is destined for Firefly’s new Florida Space Coast factory and launch site at Cape Canaveral, set to be installed by the beginning of 2022.
Firefly estimates the facility will be capable of producing 24 Alpha rockets per year, fabricated from all carbon-fiber structures including barrels, fairings, domes, and payload components, using AFP. Meanwhile, the Texas plant will transition to automated developmental builds of Firefly’s larger Beta launch vehicle. It’s estimated that the firm’s new automated rocket factories will deliver a 30-50% reduction in composite materials waste, while reducing hands-on labor, build times, and overall costs.
According to Markusic, integrating Ingersoll’s AFP technology into its production lines represents not only Firefly’s investment in its own future as a company but also in the future of the “cis-lunar space economy”, which refers to the economic activities taking place in space, either on the Moon or in orbit around the Earth.
“As Firefly approaches our first Alpha launch, our focus is transitioning to scaling our operational capabilities to meet the fast-growing commercial, government, and scientific mission demand for space access with the lightest, strongest, fastest built precision-made rocket in the industry,” he added.
The AFP Mongoose Hybrid
Firefly’s Mongoose Hybrid will be the first AFP system equipped with Ingersoll’s new Hawk fiber delivery module, which has been designed and tested with the layup of mild curvature surfaces in mind. The system will also feature Ingersoll’s automatic exchange of multiple composite manufacturing modules that perform in adjacent work areas, enabling the automation of multiple tools and lessening human intervention in the production process.
“Ingersoll has played an important role in enabling breakthrough airframe production for major aircraft designs around the world, including the 787 and A350, and we look forward to supporting Firefly and its innovative approach to the efficient and cost-effective production and further development of its Alpha, Beta, and future spacecraft,” said Chip Storie, CEO of Ingersoll Machine Tools.
“Ingersoll is thrilled to bring our vast experience in automated composite manufacturing and robotics across the aerospace industry into the world of space rocketry and exploration with Firefly.”
3D打印火箭
Additive manufacturing technologies have been used in the development and production of aerospace rockets for some time. One company which has been at the forefront of these developments is rocket-building firm相对性空间，在2015年成立之后，它迅速发展到raise $45.1 million in three years.
In 2017, the firm announced it was working on a new Stargate 3D printer which would allow it to go, “from raw material to flight in less than 60 days”, and in the long-term3D在火星上打印第一个火箭。一年后，该公司与美国空军to operate its own launch facility on one of their sites andtest its 3D printed rockets在Cape Canaveral。最近，航空航天和国防承包商要求相对空间Lockheed Martinto3D打印弹丸for an upcoming experimentalNASAmission.
Other companies operating in this space include Spanish aerospace firm零2无穷大which is using 3D printing as part of its布言气球辅助火箭和英国航空公司Orbex, which announced that its3D打印rocketswill be thefirst to launch来自2022年初英国的新太空港。在其他地方，火箭实验室3D打印Electron Rocket在该公司即将到来的任务之前，已经在其发射台上提出了U.S. Space Force，而美国初创企业Rocket Crafters已经结束了其彗星系列的测试混合3D印刷火箭引擎.
订阅3D打印行业newsletter有关增材制造中的最新消息。雷电竞充值您也可以通过关注我们来保持联系Twitterand liking us onFacebook.
请务必订阅所选播客播放器上的另一个维度播客，以确保您永远不会错过一集。
寻找添加剂制造业的职业？雷电竞充值访问3D Printing Jobsfor a selection of roles in the industry.
Featured image shows a Firefly engine test. Image via Firefly Aerospace.
