EOS and Hyperganic 3D print more efficient space propulsion components

German manufacturer EOS recently signed a partnership with Hyperganic, a Munich-based company that develops algorithmic engineering software based on artificial intelligence. The objective of this cooperation is to integrate the Hyperganic core platform with EOS 3D printing solutions and thus enable the design of complex and optimized parts for additive manufacturing processes. One of the first achievements of this strategic partnership is an aerospike rocket motor, characterized by its complex design. The motor was initially 3D printed from a nickel alloy and later made from copper in a larger volume.

Founded in 2015, Hyperganic quickly became a key player in the additive manufacturing design industry. He has developed software that can reproduce forms inspired by nature and automate every design step to the maximum degree possible. In the case of this solution, it is based on algorithms and artificial intelligence to optimize the performance of the 3D printed part. When we met with the company in 2019, their goal was to diversify their partnerships and get closer to 3D printer manufacturers. A plan that has been successfully implemented by recently signing the new agreement with EOS. Lin Kayser, CEO of Hyperganic, says: “We are very excited to partner with EOS on this industry first collaboration. Algorithmic engineering translates ideas into designs in minutes, with the engineer setting the rules and the computer generating the results. Specifically, the field of space propulsion, which still uses very conservative designs, will benefit greatly from algorithmic engineering.”

EOS and Hyperganic advance in the field of space propulsion

With that in mind, the two companies created a 3D-printed aerospike rocket engine. The Hyperganic teams came up with an innovative design based on an algorithmic model. Several hundred iterations were generated and one of them was 3D printed on an EOS M 400-4 machine, without additional support and using NickelAlloy IN718. This is a big challenge, as this type of engine requires a deconstruction of a conventional engine design and thus results in a more complex redesign. It is important to remember that aerospike nozzles are designed to optimize propulsion efficiency over a wide range of altitudes.

After this first printed part, the entire engine was modified to be manufactured on a larger system, the AMCM M 4K machine. That is a device developed by the company of the same name, which is part of EOS. It offers a production volume of ~18″ x 18″ x 40″ and integrates up to 4 lasers. The Launcher company has invested in this particular machine. In any case, an ever-larger motor of the aerospike has now been 3D printed, this time in copper.

EOS founder Dr. Hans J. Langer concludes: “As constant innovators and pioneers, we are now partnering with Hyperganic to introduce another paradigm shift in AM. It is a design change that expands solution spaces as well as performance levels. At the same time, it will revolutionize the AM design process, making AM a truly digital workflow from software-generated algorithmic engineering to digital manufacturing.” You can find the full press release HERE.

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*Cover photo credits: EOS/Hyperganic