Addithive

Category: Space

  • Binder Jetting Breakthroughs: Production Economics, Sintering and Company Exposure

    Binder Jetting Breakthroughs: Production Economics, Sintering and Company Exposure

    Updated 12 September 2026. This revision replaces the earlier 2022–2025 narrative with a source-linked production assessment.

    Metal binder jetting selectively deposits a binder into a powder bed to form a fragile green part. The subsequent thermal route consolidates the metal. Its commercial potential depends on handling yield, sintering control and accepted-part cost as much as printing speed.

    What has become commercially concrete?

    HP offers Metal Jet configurations covering development and production, with curing, powder handling and furnace operations forming part of the workflow. This is evidence of an offered industrial platform, not proof of profitability for every application. HP Metal Jet configurations and workflow.

    Binder jetting vs LPBF: compare the whole route

    Decision factorMetal binder jettingMetal LPBF
    ConsolidationBinder forms the green shape; sintering consolidates metal later.Metal melts and solidifies during printing.
    Geometry constraintsGreen-part strength, depowdering access, shrinkage and sintering distortion.Supports, thermal distortion, recoater clearance and powder escape.
    Production constraintCuring, handling, furnace loading and sintered-part yield may limit output.Build time, powder handling and downstream operations may limit output.
    Finished-part evidenceDensity, chemistry, dimensional capability and properties after the full thermal route.Properties after the specified build, thermal and finishing route.
    Commercial comparisonCompare total accepted-part cost against MIM, machining and casting.Compare total accepted-part cost and system-level design benefit.

    Five gates before calling an application production-ready

    1. Material: qualify the actual powder, binder and thermal combination. A material demonstration is not universal alloy availability.

    2. Handling: measure breakage during green-part extraction, transfer and loading. Printing without attached supports does not eliminate handling fixtures or sintering setters.

    3. Sintering: validate shrinkage compensation, distortion, carbon and oxygen control, density and furnace load consistency across representative geometries.

    4. Part release: establish dimensional inspection, surface condition, defect acceptance and mechanical-property evidence appropriate to the application.

    5. Economics: include labor, fixtures, furnace occupancy, machining, inspection, scrap and qualification costs. Avoid universal claims about speed, energy savings or break-even volume.

    Use accepted parts as the economic denominator

    For a defined production batch, divide all allocated production and quality costs by the number of released, conforming parts. Compare alternatives using the same geometry, annual volume and acceptance criteria. A faster print stage can simply move the queue to the furnace.

    Which companies are relevant?

    CompanyRoleFinancial evidence to seek
    HP Inc.Metal Jet platform and production ecosystemCustomer production adoption, recurring consumables/service demand and materiality within the broader company.
    Carpenter TechnologyMetal powder capabilitiesGrade-specific qualification, repeat powder purchases and economically meaningful revenue exposure.

    Technical sources: HP Metal Jet and Carpenter Additive. The powder-supplier example is a supply-chain research candidate; it does not establish a supplier relationship for a particular HP installation.

    Company exposure is a research starting point, not a stock recommendation. A relevant technology does not establish material revenue, attractive margins or a reasonable valuation. Check current filings, ownership, cash flow and customer concentration before drawing an investment conclusion.

    What would change the assessment?

    Stronger evidence would include named repeat-production applications, measured yield across multiple furnace loads, independent property data for the specified route and orders converted into cash. A demonstration part or announced capacity alone is weaker evidence.

    Read next: Binder jetting vs LPBF and accepted-part cost.

    Take the next step: the free AM Bottleneck Atlas

    Assess binder jetting through the full production route. The Industrial AM Bottleneck Atlas 2026 connects manufacturing constraints with qualification, economics and company exposure.

    Get the free Atlas and subscribe to the AM Bottleneck Brief →

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  • Is 3D Printing the Key to Colonizing Mars, or Just a Science Fiction Fantasy?

    Is 3D Printing the Key to Colonizing Mars, or Just a Science Fiction Fantasy?

    Since the dawn of space exploration, humanity has been fascinated by the possibility of colonizing other planets. Mars, in particular, has captured the imagination of scientists, engineers, and the general public alike. However, the challenges of establishing a human settlement on the Red Planet are enormous, and many experts believe that it will require a combination of innovative technologies to make it possible. One such technology that has been suggested as a potential key to Mars colonization is 3D printing.

    3D printing, also known as additive manufacturing, is a process in which digital 3D models are transformed into physical objects by building up layers of material. This technology has already been used to create a wide range of products, from medical implants and prosthetics to airplane parts and even entire buildings. In the context of space exploration, 3D printing has the potential to revolutionize the way that we build structures and create tools and equipment.

    One of the key advantages of 3D printing in the context of Mars colonization is the ability to manufacture objects on-site, using locally available materials. Mars is rich in resources such as iron, aluminum, and silicon, which can be used as raw materials for 3D printing. This means that instead of having to transport everything from Earth, we could potentially build many of the structures and tools needed for a Martian settlement using materials that are already on the planet. This would greatly reduce the cost and complexity of the mission, and make it more feasible in the long run.

    Another advantage of 3D printing is the ability to create complex geometries and designs that would be difficult or impossible to produce using traditional manufacturing techniques. This is particularly important in the context of space exploration, where weight and volume are at a premium. By using 3D printing to create lightweight, optimized structures, we can reduce the amount of material that needs to be transported to Mars, and make the mission more efficient.

    One of the most exciting applications of 3D printing in the context of Mars colonization is the potential to print habitats and other structures using locally sourced materials. NASA, in partnership with the University of Southern California, has already developed a prototype Mars habitat that was printed using a mixture of basaltic rock and a binding agent. This structure was designed to be strong, lightweight, and radiation-resistant, and could potentially be scaled up to create larger habitats and structures in the future.

    In addition to habitats, 3D printing could also be used to create other types of infrastructure on Mars, such as roads, landing pads, and storage facilities. These structures could be built using a variety of materials, including regolith (the loose, rocky material that covers the surface of Mars), which could be processed and used as a building material.

    However, while the potential benefits of 3D printing for Mars colonization are clear, there are also significant challenges and limitations to consider. One of the biggest challenges is the harsh environment of Mars, which presents a number of technical hurdles that must be overcome in order to make 3D printing feasible. For example, the low atmospheric pressure on Mars could make it difficult to create a stable printing environment, and the extreme temperatures could cause problems with the printing process and the materials being used.

    Another challenge is the availability and quality of local resources. While Mars has a wealth of raw materials that could be used for 3D printing, it is not yet clear how easily these materials can be processed and transformed into usable materials. There are also concerns about the quality and consistency of the materials, which could affect the strength and durability of the printed structures.

    Despite these challenges, there is a growing body of research and development focused on using 3D printing for Mars colonization. In addition to NASA’s efforts, private companies such as SpaceX and Blue Origin are also exploring the potential of 3D printing for space exploration and settlement.

    One of the key areas of research is the development of new printing materials and techniques that are specifically designed for the Martian environment. For example, researchers at the European Space Agency are exploring the use of a type of biopolymer that can be produced using bacteria and can be used as a building material for 3D printing. This material is lightweight, durable, and can be produced using organic matter that could be found on Mars.

    Another area of research is focused on creating robots and other automated systems that can operate autonomously on Mars, including the ability to perform 3D printing tasks. For example, NASA’s InSight lander has a robotic arm that could potentially be used for 3D printing tasks, while the Mars 2020 mission included a small helicopter drone that could be used to scout potential 3D printing sites.

    Despite the challenges and limitations of 3D printing for Mars colonization, there is no doubt that it has the potential to play a significant role in the future of space exploration and settlement. By allowing us to manufacture objects on-site using locally available materials, 3D printing could greatly reduce the cost and complexity of missions to Mars and other planets. It could also enable us to create structures and infrastructure that are optimized for the unique conditions of extraterrestrial environments, ultimately making it possible to establish permanent human settlements beyond Earth.

    In conclusion, while 3D printing may have once seemed like a science fiction fantasy, it is now a very real and promising technology that could play a critical role in the future of space exploration and colonization. While there are still many challenges and limitations to overcome, the potential benefits of using 3D printing for Mars colonization are too great to ignore. As researchers and engineers continue to push the boundaries of this technology, we may be one step closer to making the dream of a human settlement on Mars a reality.

  • Terran 1, world’s first 3D printed rocket Revolutionizes Aerospace

    Terran 1, world’s first 3D printed rocket Revolutionizes Aerospace

    Relativity Space writing the history by launching the world’s first 3D printed rocket, the Terran 1. This groundbreaking achievement will be a significant milestone in the aerospace industry and represents a revolutionary shift in the way we design and build rockets.

    Traditionally, rocket manufacturing has been a complex and expensive process that involves a large number of parts and specialized equipment. But with 3D printing, the potential to simplify this process and make it more cost-effective is enormous. Relativity Space has leveraged this potential to create a rocket that goes from raw material to flight, integrating artificial intelligence, robotics, and autonomous manufacturing technology.

    The Terran 1 is not only a technological marvel, but it also marks a significant shift in the aerospace industry. With 85% of its mass being 3D printed, the rocket’s primary structures are printed using a proprietary metal aluminum alloy developed in-house by Relativity. This enables the company to radically simplify the aerospace manufacturing supply chain, leading to greater flexibility and customization.

    The rocket is an expendable two-stage launch vehicle powered by liquid natural gas (LNG) and liquid oxygen (LOX) designed for future constellation deployment and resupply. It can launch up to 1,250 kilograms to low Earth orbit (LEO) for dedicated, multi-manifest and rideshare missions. With nine 3D printed Aeon 1 engines on the first stage and one 3D printed Aeon Vacuum (Vac) engine on the second stage, the rocket is 110 feet in height by 7.5 feet in diameter.

    You can watch the live launch stream above.

    The Aeon engines are fueled by liquid natural gas and liquid oxygen, utilizing the gas generator engine cycle. The tanks are autogenously pressurized with gaseous natural gas and gaseous oxygen via heat exchangers integrated into the engines. Relativity Space’s Stargate metal 3D printers enable rapid product iteration, unlocking significant improvements to product development and production.

    The potential of 3D printing in the aerospace industry is vast. The ability to print rocket parts on-demand can revolutionize the way we design and build rockets. With 3D printing, we can reduce the time it takes to produce rocket parts, reduce the cost of manufacturing, and increase the efficiency of the manufacturing process. This could lead to faster and more cost-effective space exploration.

    Relativity Space is building a highly attractive launch service offering by designing and manufacturing reusable rockets that offer high performance and reliability, while costing less to produce and fly. The company’s innovative approach to aerospace manufacturing is driving the inevitable shift toward software-defined manufacturing, which will drive innovation on and off planet Earth.

    Terran 1 – Relativityspace

    The Terran 1 launch is just the beginning of a new era in space exploration. With 3D printing and other advanced manufacturing technologies, we can revolutionize the way we explore space. The potential of additive manufacturing is vast, and we are excited to see what the future holds for this innovative technology.

    3D printing is not only a game-changer for rocket manufacturing but also for spacecraft components, satellites, and other equipment used in space exploration. This could lead to more cost-effective and efficient space missions, making it easier to explore our solar system and beyond.

    At Addithive, we are excited to see Relativity Space and other companies pushing the boundaries of what is possible with additive manufacturing. We believe that 3D printing has the potential to change the world, and we are thrilled to see how it will transform the aerospace industry and beyond.

    The Terran 1 launch is a testament to the potential of additive manufacturing to revolutionize the industry. The rocket is not only a technological marvel but also a symbol of a significant shift in the way we think about space exploration. We are excited to see what the future holds for

  • Additive Manufacturing for The New Space Age

    Additive Manufacturing for The New Space Age

    The space industry is a great field for new technology development. The challenges such as lightweight and stronger components with the demand for higher trust and lighter rockets that can reach mars propel the demand for more advanced components. Emerging technologies are almost always initiated in space or defense industries because the demand for the better originates in these industries either by war or competition in the industry. Additive Manufacturing is also incepted in the aerospace industry and there are several great examples Large rockets, aircraft engines, satellites are all requires lighter and stronger parts. and the good thing is that the production volume for industrialization of these components way lower than the automotive industry. This makes these platforms a disruptive opportunity.

    Additive manufacturing provides faster cycle time and leaner production of testing components for a space platform program. This both the design cycle of the components and the overall schedule of the development programs. Another advantage of additive manufacturing for space components is the reduction of complexity. Additive manufacturing enables the complexity of the component while reducing the complexity of the overall realization of the component. Combining several sub-parts into a combined assembly that can be built by additive manufacturing. We will go over some of the recent advancements that are developed by different NASA research centers. We will go over Rocket engine component examples that are developed with additive manufacturing technology such as injectors, turbopumps, combustion chamber and more. These advancements are great examples and paves the way to new space age for reaching Mars and beyond.

    Rocket Engine Injectors

    Rocket Engine fuel injectors are simple but one of the most critical of a rocket engine because it defines the theoretical performance of the rocket nozzle. A well-designed injector enables efficient burning of the propellant. In addition to that, injectors help to reduce the thermal loads on the nozzle by cooling the internal nozzle surface with fuel. Injectors can be made by drilling small holes with a designed pattern that fuel and oxidizers travel. The holes break the fuel into small droplets, smaller the droplets burned easily and the efficiency of the combustion increased. The holes are can be drilled in conventional ways but it is costly when compared to additive manufacturing. Rocket engine injector successfully tested at NASA Glenn research center Rocket combustion lab with a benefit of lead time from 1 year to 4 months and 70% less cost. The main cost out opportunity is to reduce the number of parts. The additive injector has 2 parts, while its conventional version has 115 parts. This is a disruptive reduction for both cost, program execution, and simplification of the supply chain.

    NASA/MSFC

    Rocket Engine Turbopumps 

    Rocket Engine Turbopumps produce high-pressure propellant to feed rocket engine combustion chamber. These pumps are designed with turbo-machinery principles and the design of these components is as hard as a jet engine yet a well-designed turbopump can deliver 70–90% efficiency. This particular turbopump makes 90000 revolutions per minute (RPM) to pump propellant. NASA has developed a turbopump in 2015 for liquid hydrogen, which is an ideal propellant for space missions but it is pumped at -240 Celcius. Rocket engine turbopump has 45% fewer parts. Combining several parts into one complex additive part dramatically reduces both costs and the weight of the component. On top of that reducing the number of parts simplifies the supply and realization of the hardware.

    This rocket engine fuel pump has hundreds of parts including a turbine that spins at over 90,000 rpms
    NASA/MSFC

    Gimbal Cone

    There are many methods to change the exhaust direction of the rockets. One of the methods is to use a gimbal system. A gimbaled nozzle tilts the engine nozzle in the proper direction. Below Gimbal cone made of titanium at ORNL, The process used for this component is Electron Beam Melting. When compared to investing casting or other conventional manufacturing methods. The manufacture of titanium components like this gimbal has a great potential to reduce costs as well as lead time and overall weight of the component. Titanium alloys are expensive yet they provide lightweight and strong components. Especially Ti-6Al-4V is a great alloy for rockets, jet engines, and satellites. Of Course, there are challenges like material properties and how are these are changing with the variation of process features. Powder Process microstructure relations are complex and need to be investigated.

    NASA

    Rocket Engine Combustion Chamber 

    Rocket fuel and oxidizer flow in to combustion chamber with the help of turbo pump since the pressure inside the combustion chamber is extremely high. The combustion chamber mixes oxidizer and the fuel. The temperatures inside of the combustion chambers is over 2750 Celcius. This is far more than the melting temperature of copper alloy. In order to protect the chamber from melting during this extreme operation, It is being cooled by the extremely low temperature (-173 Celcius ) gas circulation inside the 200 tiny channels. These channels can only be manufactured by additive technology. It takes more than 10 days to build this rocket component but it is way faster than to manufacture it with conventional ways. Copper is a good heat conducter and this makes it a great match for this application. However, it makes it hard to melt with a laser scan. Overcoming these obstacles is not easy but enables game change rocket engines.

    NASA/MSFC/Emmett Given

    Structural Jacket using EB FFF (Free Form Fabrication)

    Copper combustor liners are good for thermal conductivity but they are not very strong. In order to solve this problem, it is covered with an IN625 (Nickel Alloy) structural jacket. Electron Beam Free Form Fabrication is a directed energy deposition technology. In this technique Electron Beam is used as energy source and it is directed to melt metal wires which are IN625 for this application. It is a very fast process that is developed by Sciaky Inc to deliver 5kg/hour. EB FFF technology derived from Electron Beam welding process which has been used in aerospace industry more than 50 years. One of the challenges of this process it works under vacuum since electron beam can only be generated by vacuum.

    NASA/MSFC/David Olive

    Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) :

    NASA is working on Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) to advance novel design and manufacturing technologies while increase scale, reduce cost, and improve performance of rocket engine components. Key focus areas of the program as below :

    1. Directed Energy Deposition (DED) focusing on blown powder techniques to enable integrated cooled channel wall nozzle.
    2. Multi material additive manufacturing modalities such as bimetallic and multi-metallic deposition techniques focusing on copper and nickel based super alloys.
    3. Engineering and simulation tools to predict and compensate material feed techniques distortion and material properties
    4. Last but not least development of design tools to get full benefit of additive enables design which primarily focuses on integrated cooled combustion chamber and nozzle
    NASA

    Conclusion

    Additive manufacturing is a great tool to reduce weight and cost while improving perfomance. This is exact need for the space technology and next generation rocket engines. Several different additive modalities under investigatin by NASA and these will be utilized on space programs. we observe and extensive use of additive manufacturing technology on space propulsion componentst. There are still problems and issues to advance the technology such as certification of components and development new alloys suitable for additive manufacturing. However these issues are also good opportunities for additive manufacturing industry partners, universities and material producers.

    References :

    Additive Manufacturing of Aerospace Propulsion Components -Dr. Ajay Misra, Dr. Joe Grady and Robert Carter – NASA Glenn Research Center Cleveland, OH – Doc: 20150023067 – https://ntrs.nasa.gov/citations/20150023067

    Lightweight Thrust Chamber Assemblies using Multi- Alloy Additive Manufacturing and Composite Overwrap – Paul R. Gradl , Chris Protz   John Fikes, Allison Clark NASA Marshall Space Flight Center, Huntsville, AL Laura Evans , Sandi Miller6, David Ellis NASA Glenn Research Center, Cleveland, OH Tyler Hudson NASA Langley Research Center, Hampton, VA