Keynote Session: Dr. Jeff Rossin, Relativity Space
Senior NDE Engineer, Additive Manufacturing
Relativity Space
Long Beach, California
Wednesday, March 13 | 3:00 p.m. – 3:45 p.m.
Exhibit Hall – Industry Forum
“Wire In, Rocket out: Full Life Cycle of 3D Printing Large Format Aero Structures”
Relativity Space has developed additive manufacturing technology for the purpose of building launch vehicles among other products of interest. Terran 1, the world’s first 3D Printed Rocket (85% by mass), realized several industry firsts, most notably the use of Wire-Arc Direct-Energy Deposition to manufacture the 8’ diameter x 100’ long fracture critical primary structure.
Terran 1 launched in March of 2023, successfully passing critical mission milestones including lift off, maximum aerodynamic pressure (Max Q), and stage separation though failing to reach orbit due to a Stage 2 Engine issue. The achievements of Terran Mission 1 mark a critical demonstration of the capabilities of additive manufacturing, implementation of agile methods into hardware development and production, rapid build and qualification of additively manufactured components for service.
It furthermore provides a case study for assessing where the assumed benefits of additive manufacturing hold up, break down, and what the requirements for truly industrializing additive manufacturing for performant applications must be.
First, a review of the developmental challenges encountered in reaching this milestone will serve as the foundation to discuss the anticipated obstacles on the path to industrialization. This includes the inception, design, and qualification phases, highlighting the development of novel processes, materials, algorithms, and process optimization. The essential role of cross-disciplinary collaboration, agile methods in manufacturing, data-driven decision making, and adaptive development strategies in achieving this crucial benchmark will be covered.
Second, the remaining challenges to industrialization will be covered with a focus on scaling production, ensuring reliability, and regulatory compliance. Alignment of the technology’s performance in real-world applications will be discussed in relation to initial expectations, needs for industrialization and the lessons learned from the Terran 1 launch.
Finally, the challenges and considerations for industrialization, including economic feasibility, standardization, workforce training, and market integration will be assessed.