ILAuNCH Trailblazer project to use AM technologies to produce large-scale composite rockets

The latest Innovative Launch, Automation, Novel Materials, Communications and Hypersonics (iLAuNCH) Trailblazer project, a $180 million program building Australia’s enduring space capability through the commercialization of projects, a fast-track accelerator and skills development, is underway to apply the design flexibility and speed of additive manufacturing (AM) technology to develop large-scale carbon fiber composite structures for rockets.

“This is another world-class approach to lay up space-grade carbon fiber and then digitally model that for scale and repeatable design,” notes iLAuNCH Trailblazer executive director, Darin Lovett. “As we make progress in developing sovereign capability for space applications, we know these products will also benefit defense, aerospace and other sectors that require high-value, bespoke composite structures.”

As in past iLAuNCH projects, this one will again use the design and advanced manufacture expertise of startup company New Frontier Technologies Pty Ltd (NFT, Canberra, Australia) to create structures suitable for launch vehicle applications, along with the Australian National University’s (ANU, Canberra) Australian Advanced Instrumentation Centre (AITC), and the X-ray Computed Tomography laboratory (CTLab) for testing.

Using an ANU high-resolution CT scanner to assess and mature the manufacturing process, the collaboration will build a functional digital twin of the rocket bodies to assess, qualify and enhance the fidelity of structural models for simulation.

The application of X-ray CT and 3D multi-scale modeling at ANU will enable high-fidelity simulation. The CT will capture the detailed microstructure features, such as fiber alignment and voids, that can be reflected in the simulation models. 3D models will provide a detailed digital profile, with capability for performance simulation of every manufactured component, which is the foundation for digital certification.

The project lead, NFT, has developed design-for-manufacture (DfM) strategies for scalable AM of space-grade carbon fiber structures using laser-assisted automated tape placement (ATP).

“This is the only ATP manufacturing capability of its kind in Australia and has been proven in European (ESA) projects for manufacture of high-performance composite structures for space applications,” contends NFT director and CEO, Paul Compston.

ILAuNCH is a collaborative partnership between the University of Southern Queensland, University of South Australia and ANU, supported by the Australian Government Department of Education.