Elementum 3D is honored to align with the Rapid Analysis and Manufacturing Propulsion Technology (RAMPT) project, a public-private partnership led by NASA. The project’s goal is to use additive manufacturing (AM) methods including directed energy deposition (DED) to produce stronger and lighter rocket parts and fully understand the microstructure and properties of metal matrix composite (MMC) materials. 

Elementum 3D contributed to the RAMPT project in multiple ways. The NASA ACO RAMFIRE program extended developments from the RAMPT project. The RAMFIRE program focused on transitioning complex rocket components and launch structures from Nickel (Ni) and iron (Fe)-based superalloys to a new aluminum alloy (A6061-RAM2) and printing them in a large-scale blown powder DED print process.  

A NASA Phase III contract, awarded to Elementum 3D in 2019, printed many of the 7K and 40K L-PBF GRCop-42 chambers that were part of the RAMPT project. The scope of the effort included developing a large format AM process to optimize print quality, reliability, speed, and property characterization of GRCop-42 rocket propulsion components.  

Elementum 3D’s CTO, Dr. Jeremy Iten, participated as a chapter co-author of the Metal Additive Manufacturing for Propulsion Applications book and Elementum 3D produced some test specimens for NASA’s data collection under the RAMPT initiatives. Lead Editor Paul Gradl has stated, “Our goal with this book is provide practical lessons in successes and failures for metal AM and a basic understanding of the entire process from concept and selection through certification. AM does not stop or start at the build process alone and there is so much to understand beyond the build to apply successfully. We hope with this book AM can be applied both intentionally and methodically.”

NASA’s RAMPT project is propelling rocket propulsion manufacturing into a new era. It is already enabling engineers to print intricate assemblies of components as single pieces, dramatically reduce manufacturing times, improve component performance and reliability, and apply these advances across the space industry. 

NASA reported that the RAMPT project has achieved significant milestones utilizing new alloys and large-scale additive manufacturing processes, including 500 test-firings of 3D-printed injectors, nozzles, and chamber hardware totaling more than 16,000 seconds and 12 hot-fire tests with 3D printed thrust chamber hardware. The efforts also demonstrated a 40% weight savings using composite materials. Finally, NASA noted as a key achievement the development of a full-scale version of the RS-25 engine with the potential to reduce costs by up to 70% and cut manufacturing time in half. 

The United States Air Force Rapid Sustainment Office (RSO) recently expanded their material characterization agreement with Elementum 3D (E3D) focused on specification, dataset generation, and application testing of A6061-RAM2 for laser powder bed fusion additive manufacturing. The newly exercised Option includes as-built fatigue, as-built and machined fracture toughness and fatigue crack growth testing, stress corrosion cracking testing, wear testing, and additional tensile testing. This testing will provide a more thorough understanding of A6061-RAM2 T6 material properties for specific applications and provide a robust dataset for part design and qualification.

As part of the project, Elementum 3D is developing a full dataset based on MMPDS S-basis guidelines as well as performing additional testing to consider the impact of wall thickness, as-built surfaces, and HIP on material properties and applications. The combination of material property characterization and application studies, including non-destructive testing evaluation and a prototype part study, will provide the RSO with information they need to start qualifying parts out of A6061-RAM2 on EOS M290 printers used for this effort.

The Elementum 3D team is excited to leverage their knowledge and expertise in materials development, specifications, and printer qualification towards the success of this project. Their active involvement in AMS AM Metals and MMPDS committees will be leveraged with industry experience in specification, dataset development, and qualification for AM materials.

As AM material experts, E3D is excited to work with the RSO to produce a robust material dataset, material and process specification, and application testing to enable use of this aerospace grade aluminum and additive manufacturing to support life cycle management and sustainment of the US Air Force.

On July 20, Elementum 3D entered 15 employees along with 7 others outside the company in the “Tough Mudder” event held at Fort Carson, Colorado. All 22 competitors finished with their heads high and some bruises, scraps, and cramps.

This event went beyond running, jumping, climbing, swinging, and balancing, the “Elementum 3D Stronger, Tougher, Faster” team had to establish trust, communicate efficiently, and — most of all — lend a helping hand to conquer the 10+ mile course that included over 20 grueling and muddy obstacles.

Getting muddy together proved to be a fun way to build connections with teammates from different departments, improve company morale, and inspire some friendly competition.